Powered surgical stapler

ABSTRACT

A surgical instrument can comprise a handle, a motor, and a shaft extending from the handle. The handle and/or the shaft can define a longitudinal axis. The surgical instrument can further comprise a fastener cartridge comprising a plurality of fasteners removably stored therein, an anvil configured to deform the fasteners, a closure drive configured to move the anvil toward and away from the fastener cartridge which is rotatable about the longitudinal axis, and a firing drive configured to deploy the fasteners from the fastener cartridge which is rotatable about the longitudinal axis. The surgical instrument can further comprise a transmission comprising a first operating configuration which connects the motor to the closure drive and a second operating configuration which connects the motor to the firing drive.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming priority under35 U.S.C. § 120 to U.S. patent application Ser. No. 16/746,114 entitledPOWERED SURGICAL STAPLER, filed Jan. 17, 2020, which issued on Aug. 9,2022 as U.S. Pat. No. 11,406,381, which is a continuation applicationclaiming priority under 35 U.S.C. § 120 to U.S. patent application Ser.No. 15/869,706, entitled SURGICAL INSTRUMENT SYSTEM, filed Jan. 12,2018, which issued on Jul. 7, 2020 as U.S. Pat. No. 10,702,266, which isa continuation application claiming priority under 35 U.S.C. § 120 toU.S. patent application Ser. No. 14/248,587, entitled POWERED SURGICALSTAPLER, filed Apr. 9, 2014, which issued on Jan. 16, 2018 as U.S. Pat.No. 9,867,612, which claims the benefit under 35 U.S.C. § 119(e) of U.S.Provisional Patent Application Ser. No. 61/812,365, entitled SURGICALINSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR, filedApr. 16, 2013, of U.S. Provisional Patent Application Ser. No.61/812,376, entitled LINEAR CUTTER WITH POWER, filed Apr. 16, 2013, ofU.S. Provisional Patent Application Ser. No. 61/812,382, entitled LINEARCUTTER WITH MOTOR AND PISTOL GRIP, filed Apr. 16, 2013, of U.S.Provisional Patent Application Ser. No. 61/812,385, entitled SURGICALINSTRUMENT HANDLE WITH MULTIPLE ACTUATION MOTORS AND MOTOR CONTROL,filed Apr. 16, 2013, and of U.S. Provisional Patent Application Ser. No.61/812,372, entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONSPERFORMED BY A SINGLE MOTOR, filed Apr. 16, 2013, the entire disclosuresof which are hereby incorporated by reference herein.

BACKGROUND

Various forms of the invention relate to surgical instruments and, invarious embodiments, to surgical cutting and stapling instruments andstaple cartridges therefor that are designed to cut and staple tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of this invention and the manner ofattaining them will become more apparent and the invention itself willbe better understood by reference to the following description ofembodiments of the invention taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of a modular surgical system that includesa motor-driven surgical instrument and three interchangeable endeffectors;

FIG. 2 is a side perspective view of the motor-driven surgicalinstrument with a portion of the handle housing removed for clarity;

FIG. 3 is a partial exploded assembly view of the surgical instrument ofFIG. 2 ;

FIG. 4 is another partial exploded assembly view of the surgicalinstrument of FIGS. 2 and 3 ;

FIG. 5 is a side elevational view of the motor-driven surgicalinstrument with a portion of the handle housing removed;

FIG. 6 is a perspective view of a motor drive system and transmissionassembly with the transmission assembly in the first drive positionwherein actuation of the motor will result in the actuation of a firstdrive system of the surgical instrument of FIGS. 2-5 ;

FIG. 6A is a perspective view of an alternative transmission carriagewith locking means;

FIG. 6B is a perspective view of a motor drive system and transmissionassembly including the transmission carriage of FIG. 6A with thetransmission assembly in the first drive position wherein actuation ofthe motor will result in the actuation of the first drive system and thesecond drive system is locked by the locking means;

FIG. 6C is a perspective view of the motor drive system and transmissionassembly of FIG. 6B with the transmission assembly in the second driveposition wherein actuation of the motor will result in the actuation ofthe second drive system and the first drive system is locked by thelocking means;

FIG. 7 is another perspective view of the motor drive system andtransmission assembly of FIG. 6 with the transmission assembly in thesecond drive position wherein actuation of the motor will result in theactuation of the second drive system;

FIG. 8 is a side elevational view of another motor-driven surgicalinstrument with a portion of the handle housing and other portionsthereof omitted for clarity;

FIG. 9 is a perspective view of the motor, transmission assembly andfirst and second drive systems of the surgical instrument of FIG. 8 withthe transmission assembly thereof in the first drive position;

FIG. 10 is a cross-sectional elevational view of the motor, transmissionassembly and first and second drive systems of FIG. 9 with thetransmission assembly in the first drive position;

FIG. 11 is another perspective view of the motor, transmission assemblyand first and second drive systems of FIGS. 9 and 10 with thetransmission assembly in the second drive position;

FIG. 12 is another cross-sectional elevational view of the motor,transmission assembly and first and second drive systems of FIGS. 9-11with the transmission assembly in the second drive position;

FIG. 13 is a partial rear perspective view of a portion of another motordriven surgical instrument;

FIG. 14 is a side elevational view of the motor, transmission assemblyand first and second drive systems of the surgical instrument of FIG. 13;

FIG. 15 is a cross-sectional view of the transmission assembly of thesurgical instrument of FIGS. 13 and 14 in a first drive position;

FIG. 16 is another cross-sectional view of the transmission assembly ofthe surgical instrument of FIGS. 13-15 in a second drive position;

FIG. 17 is a perspective view of another motor driven surgicalinstrument arrangement with a portion of the housing removed forclarity;

FIG. 18 is a perspective view of a motor, transmission assembly andfirst and second drive systems of the surgical instrument of FIG. 17 ;

FIG. 19 is an exploded assembly view of the motor, transmission assemblyand first and second drive systems of FIG. 18 ;

FIG. 20 is a cross-sectional view of portions of the motor, transmissionassembly and first and second drive systems of FIGS. 18 and 19 with thetransmission shaft assembly thereof in a first drive position;

FIG. 21 is another cross-sectional view of the portions of the motor,transmission assembly and first and second drive systems of FIG. 20 withthe transmission shaft assembly thereof in a second drive position;

FIG. 22 is a perspective view of another motor, transmission assemblyand first and second drive systems of one form of a surgical instrumentof the present invention;

FIG. 23 is an exploded assembly view of the motor, transmission assemblyand first and second drive systems of FIG. 22 ;

FIG. 24 is a cross-sectional view of the motor, transmission assemblyand first and second drive systems of FIGS. 22 and 23 with thetransmission assembly in first drive position;

FIG. 25 is another cross-sectional view of the motor, transmissionassembly and first and second drive systems of FIGS. 22-24 with thetransmission assembly in a second drive position;

FIG. 26 is another cross-sectional view of the motor and transmissionassembly of FIGS. 22-25 with the transmission assembly in the firstdrive position;

FIG. 27 is another cross-sectional view of the motor and transmissionassembly of FIGS. 22-26 with the transmission assembly in the seconddrive position;

FIG. 28 is a side elevational view of a portion of another motor drivensurgical instrument with a portion of the housing omitted for clarity;

FIG. 29 is a perspective view of a portion of another motor drivensurgical instrument with a portion of the housing omitted for clarity;

FIG. 30 is a front perspective view of a motor driven unit with firstand second rotary drive systems;

FIG. 31 is a bottom perspective view of the motor driven unit of FIG. 30;

FIG. 32 is a perspective view of the motor driven unit of FIGS. 31 and32 with the housing removed therefrom;

FIG. 33 is an exploded assembly view of a mechanical coupling system foroperably coupling four rotary drive shafts together;

FIG. 34 is a front perspective view of a surgical end effector with aportion of the end effector housing removed for clarity;

FIG. 35 is another front perspective view of the surgical end effectorof FIG. 34 with portions of the closure system and lower jaw omitted forclarity;

FIG. 36 is an exploded perspective assembly view of the surgical endeffector of FIGS. 34 and 35 ;

FIG. 37 is a side elevational view of the surgical end effector of FIGS.33-36 with a portion of the housing omitted for clarity;

FIG. 38 is a left side perspective view of another end effectorarrangement with a portion of the end effector housing omitted forclarity;

FIG. 39 is an exploded assembly view of the end effector of FIG. 38 ;

FIG. 40 is a right side perspective view of the end effector arrangementof FIGS. 37 and 38 with another portion of the end effector housingomitted for clarity;

FIG. 41 is a cross-sectional view of the surgical end effectorarrangement of FIGS. 38-40 ;

FIG. 42 is a cross-sectional perspective view of another surgical endeffector;

FIG. 43 is a partial exploded assembly view of the surgical end effectorof FIG. 42 ;

FIG. 44 is another partial perspective view of a portion of the surgicalend effector of FIGS. 42 and 43 ;

FIG. 45 is another cross-sectional view of the surgical end effector ofFIGS. 42-44 ;

FIG. 46 is a perspective view of an end effector arrangement with adrive disengagement assembly;

FIG. 47 is a partial perspective view of the surgical end effector ofFIG. 46 with portions thereof omitted for clarity and with the proximaldrive train portion of the closure system detached from the distal drivetrain portion of the closure system;

FIG. 48 is a partial perspective view of the surgical end effector ofFIGS. 46 and 47 with portions thereof omitted for clarity and with thedistal coupler member seated within the slot in the proximal couplermember and the drive coupler pin removed therefrom;

FIG. 49 is another partial perspective view of the surgical end effectorof FIG. 48 showing portions of the end effector firing system;

FIG. 50 is a perspective view of another surgical end effectorarrangement;

FIG. 50A is an enlarged view of a portion of the surgical end effectorof FIG. 50 ;

FIG. 51 is a perspective view of a portion of the end effector of FIG.50 with a portion of the housing omitted for clarity;

FIG. 52 is another perspective view of the end effector of FIGS. 50 and51 with portions of the housing and closure system omitted for clarity;

FIG. 53 is another perspective view of the end effector of FIGS. 50-52with portions of the closure system and a portion of the housing omittedfor clarity;

FIG. 54 is a perspective view of another end effector that is equippedwith a drive disengagement assembly;

FIG. 55 is a side elevational view of the end effector of FIG. 54 ;

FIG. 56 is a perspective view of a portion of the end effector of FIGS.54 and 55 with a portion of the end effector housing omitted forclarity;

FIG. 57 is another perspective view of the end effector of FIGS. 54-56with the tool head thereof in a closed position;

FIG. 58 is a another partial perspective view of the end effector ofFIG. 57 with a portion of the end effector housing omitted for clarity;

FIG. 59 is another perspective view of the end effector of FIG. 58 withthe drive coupler pin removed;

FIG. 60 is another perspective view of the end effector of FIG. 59 withthe drive coupler pin removed and the closure drive beam assembly movedproximally to open the tool head;

FIG. 61 is a block diagram of a modular motor driven surgical instrumentcomprising a handle portion and a shaft portion;

FIG. 62 is a table depicting total time to complete a stroke and loadcurrent requirements for various operations of various device shafts;

FIGS. 63A and 63B illustrate a detail diagram of the electrical systemin the handle portion of the modular motor driven surgical instrument;

FIG. 64 is block diagram of the electrical system of the handle andshaft portions of the modular motor driven surgical instrument;

FIG. 65 illustrates a mechanical switching motion control system toeliminate microprocessor control of motor functions;

FIG. 66 is a perspective view of a coupling arrangement comprising acoupler housing and a pair of sockets positioned within the couplerhousing, according to various embodiments of the present disclosure;

FIG. 67 is a cross-sectional, perspective view of the couplingarrangement of FIG. 66 , depicting a pair of drive members uncoupled tothe pair of sockets and further depicting the coupling arrangement in anunlocked configuration, according to various embodiments of the presentdisclosure;

FIG. 68 is a cross-sectional, perspective view of the couplingarrangement of FIG. 66 , depicting the pair of drive members coupled tothe pair of sockets and further depicting the coupling arrangement in alocked configuration, according to various embodiments of the presentdisclosure;

FIG. 69 is a cross-sectional, perspective view of the couplingarrangement of FIG. 66 , depicting the pair of drive members coupled tothe pair of sockets and further depicting the coupling arrangement in anunlocked configuration, according to various embodiments of the presentdisclosure;

FIG. 70 is a perspective view of an insert of the coupling arrangementof FIG. 66 , according to various embodiments of the present disclosure;

FIG. 71 is a perspective view of a socket of the coupling arrangement ofFIG. 66 , according to various embodiments of the present disclosure;

FIG. 72 is a perspective view of a latch of the coupling arrangement ofFIG. 66 , according to various embodiments of the present disclosure;

FIG. 73 is a cross-sectional, perspective view of a surgical endeffector attachment for use with a surgical instrument handle, accordingto various embodiments of the present disclosure;

FIG. 74 is an exploded, perspective view of drive systems of thesurgical end effector attachment of FIG. 73 , according to variousembodiments of the present disclosure;

FIG. 75 is a perspective view of a handle for a surgical instrument,wherein the handle comprises a drive system having a first output driveassembly and a second output drive assembly, according to variousembodiments of the present disclosure;

FIG. 76 is a perspective view of the drive system of FIG. 75 , accordingto various embodiments of the present disclosure;

FIG. 77 is a cross-sectional, elevation view of the handle of FIG. 75 ,depicting the drive system engaged with the first output drive assemblyand disengaged from the second output drive assembly, according tovarious embodiments of the present disclosure;

FIG. 78 is a cross-sectional, elevation view of the drive system of FIG.75 , depicting the drive system engaged with the second output driveassembly and disengaged from the first output drive assembly, accordingto various embodiments of the present disclosure;

FIG. 79 is a partial cross-sectional perspective view of a surgicalinstrument including a rotatable drive shaft, a closure drive operableby said drive shaft, and a firing drive operable by said drive shaft,wherein the closure drive is illustrated in a partially openconfiguration and the firing drive is illustrated in an unfiredconfiguration;

FIG. 80 is a perspective view of the rotatable drive shaft of FIG. 79 ;

FIG. 81 is a partial cross-sectional perspective view of the surgicalinstrument of FIG. 79 illustrated with the closure drive in an openconfiguration and the firing drive in an unfired configuration;

FIG. 82 is a partial cross-sectional perspective view of the surgicalinstrument of FIG. 79 illustrated with the closure drive in a closedconfiguration and the firing drive in an unfired configuration;

FIG. 83 is a partial cross-sectional perspective view of the surgicalinstrument of FIG. 79 illustrated with the closure drive in a closedconfiguration and the firing drive in a fired configuration;

FIG. 84 is a partial cross-sectional perspective view of the surgicalinstrument of FIG. 79 illustrated with the firing drive in a retractedconfiguration and the closure drive in the process of being re-opened;

FIG. 85 is a partial cross-sectional view of an end effector and a shaftof a surgical instrument illustrated in a closed, unfired configuration;

FIG. 86 is a perspective view of a transmission for operating thesurgical instrument of FIG. 85 illustrated in a configuration whichcorresponds with the configuration of FIG. 85 ;

FIG. 87 is an exploded view of the transmission of FIG. 86 ;

FIG. 88 is a partial cross-sectional view of the end effector and theshaft of FIG. 85 illustrated in an open, unfired configuration;

FIG. 89 is a perspective view of the transmission of FIG. 86 illustratedin a configuration which corresponds with the configuration illustratedin FIG. 88 ;

FIG. 90 is a partial cross-sectional view of the end effector and theshaft of FIG. 85 illustrated in a closed, unfired configuration;

FIG. 91 is a perspective view of the transmission of FIG. 86 illustratedin a configuration which corresponds with the configuration illustratedin FIG. 90 ;

FIG. 92 is a partial cross-sectional view of the end effector and theshaft of FIG. 85 illustrated in a closed, fired configuration;

FIG. 93 is a perspective view of the transmission of FIG. 86 illustratedin a configuration which corresponds with the configuration illustratedin FIG. 92 ;

FIG. 94 is a perspective view of a surgical stapling instrument inaccordance with at least one embodiment;

FIG. 95 is an exploded view of a handle of the surgical staplinginstrument of FIG. 94 ;

FIG. 96 is an exploded view of an end effector of the surgical staplinginstrument of FIG. 94 ;

FIG. 97 is a partial perspective view of a motor and gear assembly ofthe surgical stapling instrument of FIG. 94 ;

FIG. 98 is a cross-sectional elevational view of the surgical staplinginstrument of FIG. 94 ;

FIG. 99 is a perspective view of a surgical stapling instrument inaccordance with at least one embodiment illustrated in an open,unlatched condition;

FIG. 100 is a perspective view of the surgical stapling instrument ofFIG. 99 illustrated in a closed, unlatched condition;

FIG. 101 is a perspective view of the surgical stapling instrument ofFIG. 99 illustrated in a closed, latched condition;

FIG. 102 is a plan view of the surgical stapling instrument of FIG. 99 ;

FIG. 103 is a cross-sectional view of the surgical stapling instrumentof FIG. 99 ;

FIG. 104 is a detail cross-sectional view of the surgical staplinginstrument of FIG. 99 ;

FIG. 105 is an exploded view of a firing drive of the surgical staplinginstrument of FIG. 99 ;

FIG. 106 is an exploded view of a closing drive of the surgical staplinginstrument of FIG. 99 ;

FIG. 107 is a cross-sectional view of a surgical stapling instrument inaccordance with at least one embodiment comprising a handle, a shaft,and an end effector;

FIG. 108 is a cross-sectional view of the handle of the surgicalstapling instrument of FIG. 107 illustrated in an open configuration;

FIG. 109 is a cross-sectional view of the handle of the surgicalstapling instrument of FIG. 107 illustrated in a closed configuration;

FIG. 110 is a perspective view of the handle of the surgical staplinginstrument of FIG. 107 illustrated with some components removed;

FIG. 111 is a perspective view of a surgical stapling instrument inaccordance with at least one embodiment comprising a handle and a shaft;

FIG. 112 is a perspective view of the surgical stapling instrument ofFIG. 111 illustrating the handle detached from the shaft;

FIG. 113 is an exploded view of the surgical stapling instrument of FIG.111 ;

FIG. 114 is a partial cross-sectional view of the handle of FIG. 111illustrating a transmission operably engaged with a closure system ofthe surgical stapling instrument of FIG. 111 ;

FIG. 115 is a partial cross-sectional view of the handle of FIG. 111illustrating the transmission of FIG. 114 operably engaged with a firingsystem of the surgical stapling instrument of FIG. 111 ;

FIG. 116 is an exploded view of the transmission of FIG. 114 ;

FIG. 117 is a perspective view of a surgical stapling instrument inaccordance with at least one embodiment illustrated with some componentsremoved and illustrated in an open configuration;

FIG. 118 is a perspective view of the surgical stapling instrument ofFIG. 117 illustrated with some components removed and illustrated in aclosed configuration;

FIG. 119 is a perspective view of another end effector arrangement and astaple pack embodiment therefor prior to installing the staple pack intothe end effector;

FIG. 120 is another perspective view of the end effector and staple packof FIG. 119 with the staple pack installed into the end effector; and

FIG. 121 is another perspective view of the end effector and staple packof FIG. 120 with the keeper member of the staple pack removed therefrom.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate preferred embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/782,295, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL COMMUNICATION,now U.S. Pat. No. 9,700,309;

U.S. patent application Ser. No. 13/782,323, entitled ROTARY POWEREDARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,782,169;

U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL SWITCHARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2014/0249557;

U.S. patent application Ser. No. 13/782,499, entitled ELECTROMECHANICALSURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT, now U.S. Pat. No.9,358,003;

U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE PROCESSORMOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,554,794;

U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK SWITCHASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Pat. No. 9,326,767;

U.S. patent application Ser. No. 13/782,481, entitled SENSORSTRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now U.S. Pat.No. 9,468,438;

U.S. patent application Ser. No. 13/782,518, entitled CONTROL METHODSFOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS, now U.S.Patent Application Publication No. 2014/0246475;

U.S. patent application Ser. No. 13/782,375, entitled ROTARY POWEREDSURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM, now U.S. Pat. No.9,398,911; and

U.S. patent application Ser. No. 13/782,536, entitled SURGICALINSTRUMENT SOFT STOP, now U.S. Pat. No. 9,307,986, are herebyincorporated by reference in their entireties.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/803,097, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now U.S. Pat. No.9,687,230;

U.S. patent application Ser. No. 13/803,193, entitled CONTROLARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now U.S. Pat.No. 9,332,987;

U.S. patent application Ser. No. 13/803,053, entitled INTERCHANGEABLESHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT, now U.S. Pat. No.9,883,860;

U.S. patent application Ser. No. 13/803,086, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. PatentApplication Publication No. 2014/0263541;

U.S. patent application Ser. No. 13/803,210, entitled SENSORARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS,now U.S. Pat. No. 9,808,244;

U.S. patent application Ser. No. 13/803,148, entitled MULTI-FUNCTIONMOTOR FOR A SURGICAL INSTRUMENT, now U.S. Pat. No. 10,470,762;

U.S. patent application Ser. No. 13/803,066, entitled DRIVE SYSTEMLOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,629,623;

U.S. patent application Ser. No. 13/803,117, entitled ARTICULATIONCONTROL SYSTEM FOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Pat. No.9,351,726;

U.S. patent application Ser. No. 13/803,130, entitled DRIVE TRAINCONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,351,727; and

U.S. patent application Ser. No. 13/803,159, entitled METHOD AND SYSTEMFOR OPERATING A SURGICAL INSTRUMENT, now U.S. Pat. No. 9,888,919.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 25, 2014 and are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/226,106, entitled POWER MANAGEMENTCONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2015/0272582;

U.S. patent application Ser. No. 14/226,099, entitled STERILIZATIONVERIFICATION CIRCUIT, now U.S. Pat. No. 9,826,977;

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U.S. patent application Ser. No. 14/226,117, entitled POWER MANAGEMENTTHROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP CONTROL, now U.S.Pat. No. 10,013,049;

U.S. patent application Ser. No. 14/226,075, entitled MODULAR POWEREDSURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES, now U.S. Pat. No.9,743,929;

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U.S. patent application Ser. No. 14/226,116, entitled SURGICALINSTRUMENT UTILIZING SENSOR ADAPTATION, now U.S. Patent ApplicationPublication No. 2015/0272571;

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U.S. patent application Ser. No. 14/226,133, entitled MODULAR SURGICALINSTRUMENT SYSTEM, now U.S. Patent Application Publication No.2015/0272557;

U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS ANDMETHODS FOR CONTROLLING A SEGMENTED CIRCUIT, now U.S. Pat. No.9,804,618;

U.S. patent application Ser. No. 14/226,076, entitled POWER MANAGEMENTTHROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE PROTECTION, now U.S. Pat.No. 9,733,663;

U.S. patent application Ser. No. 14/226,111, entitled SURGICAL STAPLINGINSTRUMENT SYSTEM, now U.S. Pat. No. 9,750,499; and

U.S. patent application Ser. No. 14/226,125, entitled SURGICALINSTRUMENT COMPRISING A ROTATABLE SHAFT, now U.S. Pat. No. 10,201,364.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/248,590, entitled MOTOR DRIVENSURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now U.S. Pat. No.9,826,976;

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U.S. patent application Ser. No. 14/248,584, entitled MODULAR MOTORDRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR ALIGNING ROTARYDRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS, now U.S. Pat. No.9,801,626;

U.S. patent application Ser. No. 14/248,586, entitled DRIVE SYSTEMDECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. Pat. No.10,136,887; and

U.S. patent application Ser. No. 14/248,607, entitled MODULAR MOTORDRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION ARRANGEMENTS, nowU.S. Pat. No. 9,814,460.

Certain exemplary embodiments will now be described to provide anoverall understanding of the principles of the structure, function,manufacture, and use of the devices and methods disclosed herein. One ormore examples of these embodiments are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thedevices and methods specifically described herein and illustrated in theaccompanying drawings are non-limiting exemplary embodiments and thatthe scope of the various embodiments of the present invention is definedsolely by the claims. The features illustrated or described inconnection with one exemplary embodiment may be combined with thefeatures of other embodiments. Such modifications and variations areintended to be included within the scope of the present invention.

Reference throughout the specification to “various embodiments,” “someembodiments,” “one embodiment,” or “an embodiment”, or the like, meansthat a particular feature, structure, or characteristic described inconnection with the embodiment is included in at least one embodiment.Thus, appearances of the phrases “in various embodiments,” “in someembodiments,” “in one embodiment”, or “in an embodiment”, or the like,in places throughout the specification are not necessarily all referringto the same embodiment. Furthermore, the particular features,structures, or characteristics may be combined in any suitable manner inone or more embodiments. Thus, the particular features, structures, orcharacteristics illustrated or described in connection with oneembodiment may be combined, in whole or in part, with the featuresstructures, or characteristics of one or more other embodiments withoutlimitation. Such modifications and variations are intended to beincluded within the scope of the present invention.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical”, “horizontal”, “up”, and“down” may be used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, theperson of ordinary skill in the art will readily appreciate that thevarious methods and devices disclosed herein can be used in numeroussurgical procedures and applications including, for example, inconnection with open surgical procedures. As the present DetailedDescription proceeds, those of ordinary skill in the art will furtherappreciate that the various instruments disclosed herein can be insertedinto a body in any way, such as through a natural orifice, through anincision or puncture hole formed in tissue, etc. The working portions orend effector portions of the instruments can be inserted directly into apatient's body or can be inserted through an access device that has aworking channel through which the end effector and elongated shaft of asurgical instrument can be advanced.

Turning to the Drawings wherein like numerals denote like componentsthroughout the several views, FIG. 1 depicts a modular surgicalinstrument system generally designated as 2 that, in one form, includesa motor driven surgical instrument 10 that may be used in connectionwith a variety of surgical end effectors such as, for example, endeffectors 1000, 2000 and 3000. In the illustrated embodiment, the motordriven surgical instrument 10 includes a housing 12 that consists of ahandle 14 that is configured to be grasped, manipulated and actuated bya clinician. As the present Detailed Description proceeds, it will beunderstood that the various unique and novel drive system arrangementsdepicted in connection with handle 14 as well as the various endeffector arrangements disclosed herein may also be effectively employedin connection with robotically-controlled surgical systems. Thus, theterm “housing” may also encompass a housing or similar portion of arobotic system that may house or otherwise operably support variousforms of the drive systems depicted herein and which may be configuredto generate control motions which could be used to actuate the endeffector arrangements described herein and their respective equivalentstructures. The term “frame” may refer to a portion of a handheldsurgical instrument. The term “frame” may also represent a portion of amotor driven system or a robotically controlled surgical instrumentand/or a portion of the robotic system that may be used to operablycontrol a surgical instrument. For example, the drive systemarrangements and end effector arrangements disclosed herein may beemployed with various robotic systems, instruments, components andmethods disclosed in U.S. patent application Ser. No. 13/118,241,entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, which is hereby incorporatedby reference herein in its entirety.

Referring now to FIGS. 2-5 , the handle 14 may comprise a pair of handlehousing segments 16 and 18 that may be interconnected by screws, snapfeatures, adhesive, etc. In the illustrated arrangement, the handlehousing segments 16, 18 cooperate to form a pistol grip portion 19 thatcan be gripped and manipulated by the clinician. As will be discussed infurther detail below, the handle 14 operably supports two rotary drivesystems 20, 40 therein that are configured to generate and apply variouscontrol motions to corresponding drive shaft portions of a particularend effector coupled thereto. The first rotary drive system 20 may, forexample, be employed to apply “closure” motions to a correspondingclosure drive shaft arrangement that is operably supported in an endeffector and the second rotary drive system 40 may be employed to apply“firing” motions to a corresponding firing drive shaft arrangement inthe end effector that is coupled thereto.

The first and second rotary drive systems 20, 40 are powered by a motor80 through a unique and novel “shiftable” transmission assembly 60 thatessentially shifts power/motion between two power trains. The firstrotary drive system 20 includes a first rotary drive shaft 22 that isrotatably supported in the housing 12 of the handle 14 and defines afirst drive shaft axis “FDA-FDA”. A first drive gear 24 is keyed onto orotherwise non-rotatably affixed to the first rotary drive shaft 22 forrotation therewith about the first drive shaft axis FDA-FDA. Similarly,the second rotary drive system 40 includes a second rotary drive shaft42 that is rotatably supported in the housing 12 of the handle 14 anddefines a second drive shaft axis “SDA-SDA”. In at least onearrangement, the second drive shaft axis SDA-SDA is offset from andparallel or is substantially parallel to the first drive shaft axisFDA-FDA. As used in this context, the term “offset” means that the firstand second drive shaft axes are not coaxial for example. The secondrotary drive shaft 42 has a second drive gear 44 keyed onto or otherwisenon-rotatably affixed to the second drive shaft 42 for rotationtherewith about the second drive shaft axis SDA-SDA. In addition, thesecond drive shaft 42 has an intermediate drive gear 46 rotatablyjournaled thereon such that the intermediate drive gear 46 is freelyrotatable on the second rotary drive shaft 42 about the second driveshaft axis SDA-SDA.

Referring to FIGS. 2-5 , in one form, the motor 80 includes a motoroutput shaft 81 that has a motor drive gear 82 non-rotatably attachedthereto. The motor drive gear 82 is configured for intermeshing“operable” engagement with the transmission assembly 60 as will bediscussed in further detail below. In at least one form, thetransmission assembly 60 includes a transmission carriage 62 that issupported for axial travel between the drive gear 82 and gears 44 and 46on the second rotary drive shaft 42. For example, the transmissioncarriage 62 may be slidably journaled on a support shaft 63 that ismounted within the housing 12 on a shaft mount 61 such that the line ofaction of the transmission carriage is perpendicular to the gear trainsof the rotary drive systems. The shaft mount 61 is configured to berigidly supported within slots or other features within the housing 10.The transmission carriage 62 includes a carriage gear 64 that isrotatably supported on the support shaft 63 and is configured forselective meshing engagement with gears 44 and 46 while in drivingengagement with drive gear 82. In the arrangement depicted in FIGS. 2-5, the transmission carriage 62 is operably attached to a shifter or a“means for shifting” 70 that is configured to axially shift thetransmission carriage 62 between a “first drive position” and a “seconddrive position”. In one form, for example, the means for shifting 70includes a shifter solenoid 71 that is supported within the housing 12of the handle 14. The shifter solenoid 71 may comprise a bi-stablesolenoid or, for example, may comprise a “dual position, spring loaded”solenoid. The illustrated arrangement, for example, includes a spring 72that biases the transmission carriage 62 in the distal direction “DD” tothe first drive position wherein the carriage gear 64 is in meshingengagement with the intermediate drive gear 46 while also in meshingengagement with the drive gear 82. When in that first drive position,activation of the motor 80 will result in rotation of gears 82, 46 and24 which will ultimately result in rotation of the first drive shaft 22.As will be further discussed herein, the shifter solenoid 71 may beactuated by a firing trigger 90 that is pivotally supported on thehousing 12 of handle 14 as shown in FIGS. 2 and 5 . In the illustratedembodiment, the firing trigger 90 is pivotally supported on a firingtrigger shaft 92 mounted in the handle 14. The firing trigger 90 isnormally biased in an unactuated position by a firing trigger spring 94.See FIG. 3 . The firing trigger 90 is mounted for operable actuation ofa firing switch 96 that is operably supported on a control circuit boardassembly 100. In the illustrated arrangement, actuation of the firingtrigger 90 results in the actuation of the shifter solenoid 71. Asdescribed in more detail hereinbelow in connection with FIGS. 61, 63A,63B, 64 , the handle processor 7024 provides the drive signal to shiftersolenoid 7032 (71). With reference now back to FIGS. 2-5 , thus,actuation of the firing trigger 90 will result in the shifter solenoid71 pulling the transmission carriage 62 in the proximal direction “PD”to thereby move the carriage gear 64 into meshing engagement with thesecond drive gear 44. See FIG. 7 . Actuation of motor 80 when thecarriage gear 64 is in meshing engagement with the drive gear 82 and thesecond drive gear 44 will result in the rotation of the second driveshaft 42 about the second drive shaft axis “SDA”. As can also be seen inFIGS. 2-5 , the shiftable transmission assembly 60 may also include anindicator system 74 that includes a pair of switches 75 and 76 that areoperably coupled to the control board 100 as well as a transmissionindicator light 77. The switches 75, 76 serve to detect the position ofthe transmission carriage 62 which results in the control systemactuating the indicator light 77 depending upon the position of thetransmission carriage 62. For example, the indicator light 77 may beenergized when the transmission carriage 62 is in the first driveposition. This provides the clinician with an indication that actuationof the motor 80 will result in the actuation of the first drive system20.

Various surgical instruments disclosed herein may also include atransmission assembly 60′ that is substantially identical totransmission assembly 60, but also include a locking assembly or means(generally designated as 65) for locking the first and second drivesystems 20, 40 to prevent their inadvertent actuation when they are notintended to be actuated. For example, FIG. 6A illustrates an alternativetransmission carriage 62′ that includes a first drive lock 66 and asecond drive lock 68. The first drive lock 66 comprises a first gearengagement member or tooth on the transmission carriage 62′ that islocated for intermeshing engagement with the second drive gear 44 whenthe carriage gear 64 is in driving engagement with the intermediate gear46 (i.e., when the transmission assembly 60′ is in the first driveposition). See FIG. 6B. Thus, when the transmission assembly 60′ is inthe first drive position, the first drive lock 66 is in meshingengagement with the second drive gear 44 and prevents relative rotationthereof while the first drive shaft 22 is rotated in the above-describedmanner. Likewise, when the transmission assembly 60′ is in the seconddrive position (i.e., the carriage gear 64 is in meshing engagement withthe second drive gear 44), the second drive lock 68 is in meshingengagement with the intermediate drive gear 46. See FIG. 6C. Thus, whenthe transmission assembly 60′ is in the second drive position, thesecond drive lock 68 prevents the intermediate gear 46 from rotatingwhich also prevents the first drive gear 24 from rotating. As such, whenthe clinician operates the motor 80 to actuate the first drive system20, the second drive system 40 is locked in position. Likewise, when theclinician actuates the second drive system 40, the first drive system 20is locked in position.

The control system for the motor 80, as described hereinbelow inconnection with FIGS. 61, 63A, 63B, 64 , may be programmed in such a waythat it always stops in an orientation when one tooth of gears 42, 44remains vertical or other defined position depending upon theorientation of the other matching gear. This feature will serve to avoidany interference between the gear teeth while shifting. When shifting,the locking members also shift and locks the position of thenon-rotating gear train. When employed in connection with an endeffector that includes a cartridge/anvil arrangement or other clampingconfiguration, another advantage gained by locking the non-rotating(i.e., non-powered) gear train is the retention of the clamp/anvil in astable position while firing.

The motor 80 may be a DC brushed driving motor having a maximum rotationof, approximately, 25,000 RPM, for example. In other arrangements, themotor may include a brushless motor, a cordless motor, a synchronousmotor, a stepper motor, or any other suitable electric motor, includingmotors which can be autoclavable. The motor 80 may be powered by a powersource 84 that in one form may comprise a power pack 86 that isremovably stored in the handle 14. As can be seen in FIGS. 2-5 , forexample, the power pack 86 may be removably housed within the pistolgrip portion 19 of the handle 14. To access the power pack 86, theclinician removes a removable cap 17 that is attached to the pistol gripportion 19 as shown. The power pack 86 may operably support a pluralityof batteries (not shown) therein. The batteries may each comprise, forexample, a Lithium Ion (“LI”) or other suitable battery. The power pack86 is configured for removable operable attachment to the controlcircuit board assembly 100 which is also operably coupled to the motor80 and mounted within the handle 14. A number of batteries may beconnected in series may be used as the power source for the surgicalinstrument. In addition, the power source 84 may be replaceable and/orrechargeable and, in at least one instance, can include CR123 batteries,for example. The motor 80 may be actuated by a “rocker-trigger” 110 thatis pivotally mounted to the pistol grip portion 19 of the handle 14. Therocker trigger 110 is configured to actuate a first motor switch 112that is operably coupled to the control board 100. The first motorswitch 112 may comprise a pressure switch which is actuated by pivotingthe rocker trigger 110 into contact therewith. Actuation of the firstmotor switch 112 will result in actuation of the motor 80 such that thedrive gear 82 rotates in a first rotary direction. A second motor switch114 is also attached to the circuit board 100 and mounted for selectivecontact by the rocker trigger 110. Actuation of the second motor switch114 will result in actuation of the motor 80 such that the drive gear 82is rotated in a second direction. For example, in use, a voltagepolarity provided by the power source 84 can operate the electric motor80 in a clockwise direction wherein the voltage polarity applied to theelectric motor by the battery can be reversed in order to operate theelectric motor 80 in a counter-clockwise direction. As with the otherforms described herein, the handle 14 can also include a sensor that isconfigured to detect the directions in which the drive systems are beingmoved. One particular implementation of the motor 80 is describedhereinbelow in connection with FIGS. 61, 63A, 63B, 64 where a brushlessDC motor 7038 is described. DC motor 7038 can be autoclavable.

FIGS. 8-12 illustrate another form of surgical instrument 10′ that maybe identical to surgical instrument 10 except for the differences notedbelow. Those components of surgical instrument 10′ that are the same asthe components in the surgical instrument 10 described above will bedesignated with the same element numbers. Those components of surgicalinstrument 10′ that may be similar in operation, but not identical tocorresponding components of surgical instrument 10, will be designatedwith the same component numbers along with a “′” or in some cases a “″”.As can be seen in FIG. 8 , for example, the first drive shaft axis “FDA”is offset from and parallel with or is substantially parallel with thesecond drive shaft axis “SDA”. Referring primarily to FIG. 9 , forexample, the transmission assembly 60 and, more specifically, thetransmission carriage 62″ is manually shiftable by a linkage assembly120 that is operably attached to the firing trigger 90′. As can be seenin that Figure, for example, the linkage assembly 120 includes a firsttransmission link 122 that is pivotally coupled to the firing trigger90′ and extends axially to be pivotally coupled to a transmission yoke124. The transmission yoke 124 is movably pinned to the transmissioncarriage 62″. Thus, actuation of the firing trigger 90′ results in theaxial movement of the transmission carriage 62″. It will therefore beunderstood that the linkage assembly 120 essentially performs similaractuation motions to those performed by the shifter solenoid 71 that wasdescribed above. As used in the context of this embodiment with respectto movement of the transmission carriage 62″, the term “manuallyshiftable” refers to moving the transmission carriage between the firstand second drive positions without the use of electricity or other powermeans other than depressing the firing trigger 90′.

As can also be seen in FIGS. 8-12 , the second drive gear 44′ is spacedapart from the intermediate gear 46′ on the second drive shaft 42′ by aspacer 45. The second drive gear 44′ is keyed onto or otherwisenon-rotatably affixed to the second drive shaft 42′, while theintermediate drive gear 46′ is rotatably journaled on the second driveshaft 42′ for free rotation relative thereto. In one form, for example,a distal drive gear 130 is supported in meshing engagement with theintermediate drive gear 46′. Similarly, a proximal drive gear 136 issupported in meshing engagement with the second drive gear 44′. In thisarrangement, however, the transmission carriage 62″ also includes acentrally-disposed, transmission gear assembly 140 that is operablyattached to the transmission carriage 62′ for axial travel therewith.Still referring to FIGS. 8-12 , the transmission gear assembly 140includes a centrally-disposed shifter drive gear 142 that is in slidablemeshing engagement with the motor drive gear 82. Thus, rotation of motordrive gear 82 results in rotation of the shifter drive gear 142. Inaddition, a proximally extending, conically-shaped drive gear 144 iscoupled to the shifter drive gear 142 and is configured for selectivemeshing engagement with a proximal gear socket 146 that is attached tothe proximal drive gear 136. Likewise a distally extending, conicallyshaped drive gear 148 is configured for selective meshing engagementwith a distal gear socket 150 attached to the distal drive gear 130.

When the clinician desires to actuate the first drive system 20, theclinician moves the firing trigger 90′ to axially move the transmissiongear assembly 140 to bring the distally extending conically-shaped drivegear 148 into seated meshing engagement with the distal gear socket 150that is attached to distal drive gear 130. See FIGS. 8-10 . When in thatposition, operation of motor 80 will result in the rotation of motordrive gear 82, shifter drive gear 142, distal drive gear 130,intermediate drive gear 46′, the first drive gear 24 and the first driveshaft 22. When the clinician desires to actuate the second drive system40, the clinician moves the firing trigger 90′ to the position shown inFIGS. 11 and 12 to thereby bring the proximally extendingconically-shaped drive gear 144 into seated meshing engagement with theproximal gear socket 146 that is attached to the proximal drive gear136. When in that position, operation of motor 80 will result in therotation of drive gear 82, shifter drive gear 142, proximal drive gear136, the second drive gear 44′ and the second drive shaft 42′. As canalso be seen in FIGS. 8-12 , sensors 152 and 154 may be employed todetect the position of the transmission carriage 62″ as will bediscussed in further detail below. For example, the sensors 152 and 154may be implemented using the Hall effect sensors 7028 describedhereinbelow in connection with FIGS. 61, 63A, 63B, 64 .

FIGS. 13-16 illustrate another form of motor driven surgical instrument310 that may be identical to surgical instrument 10 except for thedifferences noted below. Those components of surgical instrument 310that are the same as the components in the surgical instrument 10described above will be designated with the same element numbers. Inthis arrangement, the first and second drive systems 20, 40 are poweredby motor 80 through a unique and novel “shiftable” transmission assembly360. The first drive system 20 includes a first drive shaft 22 that hasa first drive pulley 324 keyed thereon or otherwise non-rotatablyaffixed thereto. Similarly, the second drive system 40 includes a seconddrive shaft 42 that has a second drive pulley 344 keyed thereon orotherwise non-rotatably thereto. As can be seen in FIG. 14 , forexample, the first drive shaft axis “FDA” is offset from and parallelwith or is substantially parallel with the second drive shaft axis“SDA”.

Still referring to FIGS. 13-16 , in one form, the motor 80 includes afirst motor pulley 382 that is non-rotatably attached to the shaft ofthe motor 80. The first motor pulley 382 drives a first drive belt 385that is received on the first drive pulley 324. In addition, a secondmotor pulley 384 is non-rotatably mounted to the motor shaft andoperably supports a second drive belt 387 thereon. The second drive belt387 is also received on the second drive pulley 344 on the second driveshaft 42. The first and second drive belts 385, 387 may compriseV-belts, for example.

The instrument 310 also includes a transmission assembly 360 thatincludes a transmission carriage 362 that is supported for axial travelwithin the instrument housing. The transmission carriage 362 operablyinteracts with an idler carriage 374 that is supported to move laterallyin response to contact with transmission carriage 362 as thetransmission carriage 362 is moved axially by the shifter solenoid 71.The idler carriage 374 includes a first idler pulley 375 and a secondidler pulley 376 mounted thereon. In the illustrated arrangement, thespring 72 biases the transmission carriage 362 in the distal direction“DD” to a first drive position wherein the transmission carriage 362causes the idler carriage 374 to move in a first lateral direction “FLD”which causes the first idler pulley 375 to remove the slack from thefirst drive belt 385. When in that position, the second idler pulley 376is located out of engagement with the second drive belt 387. Thus,operation of motor 80 will result in the rotation of the first driveshaft 22. Although the second motor pulley 384 will also be rotated whenthe motor 80 is activated, the slack in the second drive belt 387prevents that rotary motion from being transferred to the second drivepulley 344. Thus, no rotary motion is transferred to the second drivesystem 40. As discussed above, the shifter solenoid 71 may be actuatedby the firing trigger 90. However, in alternative arrangements, theshifter solenoid 71 may also be replaced by a manually actuatablelinkage assembly of the type described above, for example. In theillustrated arrangement, actuation of the firing trigger 90 will resultin the shifter solenoid 71 pulling the transmission carriage 362 in theproximal direction “PD” to thereby laterally displace the idler carriage374 in a second lateral direction “SLD” to bring the second idler 376into contact with the second drive belt 387 to remove the slacktherefrom. Such lateral movement of the idler carriage 374 also movesthe first idler 375 out of engagement with the first drive belt 385 topermit the first drive belt 385 to slacken. Thus, when in such seconddrive position, actuation of the motor 80 results in the actuation ofthe second drive system 40. The slack in the first drive belt 385prevents the rotary motion from being transferred to the first drivesystem 20.

The transmission assembly 360 may provide several distinct advantages.For example, the use of V-belts eliminates meshing gears or gearalignments with a clutch. Furthermore, such transmission arrangement maybe activated or deactivated under load. In addition, the transmissionassembly 360 requires little displacement to disengage and engage.

FIGS. 17-21 illustrate another form of motor driven surgical instrument410 that may be identical to surgical instrument 10 except for thedifferences noted below. Those components of surgical instrument 410that are the same as the components in the surgical instrument 10described above will be designated with the same element numbers. Inthis arrangement, the first and second drive systems 20, 40 are poweredby motor 480 through a unique and novel “shiftable” transmissionassembly 460. The first drive system 20 includes a first drive shaft 22that has a first drive pulley 424 keyed thereon or otherwisenon-rotatably affixed thereto. Similarly, the second drive system 40includes a second drive shaft 42 that has a second drive pulley 444keyed thereon or otherwise non-rotatably fixed thereto. As can be seenin FIG. 18 , for example, the first drive shaft axis “FDA” is offsetfrom and parallel with or is substantially parallel with the seconddrive shaft axis “SDA”.

Referring now to FIG. 19 , in one form, the motor 480 includes a splineddrive shaft 481 that is adapted to slidably engage a transmission shaftassembly 490 that is configured to interact with a transmission carriage462 such that axial movement of the transmission carriage 462 results inaxial movement of the transmission shaft assembly 490 on the splineddrive shaft 481. As can be seen in FIG. 19 , the transmission shaftassembly 490 has a splined bore 491 therein for slidably and operablyreceiving the splined drive shaft 481 therein. In addition, a distalengagement collar 492 is formed on a distal end of the transmissionshaft assembly 490. The distal engagement collar 492 is configured withan annular groove 493 that is configured to receive therein two opposedyoke rods 465 that are attached to a yoke portion 464 of thetransmission carriage 462. Such arrangement serves to couple thetransmission carriage 462 to the transmission shaft assembly 490 whilepermitting the transmission shaft assembly 490 to rotate relative to thetransmission carriage 462.

Still referring to FIG. 19 , a first motor pulley 482 is configured forselective driving engagement with the transmission shaft assembly 490.As can be seen in FIG. 19 , for example, the transmission shaft assembly490 has a bearing collar 494 formed on the proximal end thereof that issized to be slidably and rotatably received within bore 483 in the firstmotor pulley 482. In addition, the first motor pulley 482 also includesa star-shaped proximal drive cavity 488 that is adapted to meshinglyengage a complementary-shaped drive portion 495 formed on thetransmission shaft assembly 490. The first motor pulley 482 drives afirst drive belt 485 that is also received on the first drive pulley424. The surgical instrument 410 also includes a second motor pulley 484that has a star-shaped bore 489 that is configured to meshingly engagethe drive portion 495 of the transmission shaft assembly 490 therein. Asecond motor pulley 484 operably supports a second drive belt 487thereon that is also received on the second drive pulley 444.

As indicated above, the instrument 410 also includes a transmissionassembly 460 that includes a transmission carriage 462 that is supportedfor axial travel within the instrument housing. The transmissioncarriage 462 operably interacts with transmission shaft assembly 490 toalso move the transmission shaft assembly 490 axially while thetransmission shaft assembly 490 remains engaged with the motor shaft481. FIG. 20 illustrates the shifter solenoid 71 in the unactuatedposition. As can be seen in that Figure, the transmission carriage 462has moved the transmission shaft assembly 490 to its proximal-mostposition which may also be referred to as the “first drive position”wherein the drive portion 495 is in driving engagement with thestar-shaped bore 488 in the first motor pulley 482. Thus, rotation ofthe motor shaft 481 will result in rotation of the transmission shaftassembly 490 and the first motor pulley 482. Rotation of the first motorpulley 482 results in rotation of the first drive belt 485 whichultimately results in rotation of the first drive shaft 22. When thetransmission shaft assembly 490 is in the first drive position, thetransmission shaft assembly 490 rotates freely relative to the secondmotor pulley 484. Thus, when the first drive system 20 is actuated, thesecond drive system 40 remains unactuated. When the shifter solenoid 71is actuated to the position shown in FIG. 21 (by actuating the firingtrigger 90), the transmission carriage 462 moves the transmission shaftassembly 490 to its distal-most position on the motor shaft 481 whichmay also be referred to as the ‘second drive position”. As can be seenin FIG. 21 , when the transmission shaft assembly 490 is in the seconddrive position, the drive portion 495 thereof is moved into meshingengagement with the star-shaped bore 489 in the second motor pulley 484.Thus, rotation of the motor shaft 481 will result in the rotation of thesecond motor pulley 484. Rotation of the second motor pulley 484 willresult in the rotation of the second drive belt 487 which results in therotation of the second drive shaft 42. When in that second driveposition, the transmission shaft assembly 490 rotates freely within thefirst motor pulley 482. Thus, when the second drive system 40 isactuated, the first drive system 20 is in an unactuated state.

FIGS. 22-27 illustrate another motor, transmission assembly and firstand second drive systems that may be employed with various surgicalinstruments described herein. The illustrated arrangement includes amotor 580 that has a motor shaft 581. See FIGS. 23 and 24 . A motordrive gear 582 or “sun gear” 582 is non-rotatably affixed to the motorshaft 581 for rotation therewith. The arrangement further includes aplanetary gear assembly 570 that includes three planetary gears 572 thatare rotatably supported between a distal carrier bracket 573 andproximal carrier bracket 574. The proximal carrier bracket 574 issupported on a hub portion of the sun gear 582 such that the sun gear582 may rotate relative to the proximal carrier bracket 574. The distalcarrier bracket 573 is affixed to a second drive shaft 542 of a seconddrive system 40 such that rotation of the distal carrier bracket 573will result in the rotation of the second drive shaft 542 of the seconddrive system 40. The three planetary gears 572 are supported in meshingengagement with a ring gear assembly 575. More specifically, theplanetary gears 572 are in meshing engagement with an internal ring gear576 on the ring gear assembly 575. The ring gear assembly 575 furtherincludes an external ring gear 577 that is in meshing engagement with afirst drive gear 524 that is affixed to a first drive shaft 522 of thefirst drive system 20. As can be seen in FIG. 24 , for example, thefirst drive shaft axis “FDA” is offset from and parallel with or issubstantially parallel with the second drive shaft axis “SDA”.

As can be seen in FIG. 23 , the arrangement further includes a solenoid71 that may be operated by the firing trigger in the various mannersdescribed herein. In this arrangement, the transmission assembly 560 isattached to the shaft 73 of the solenoid 71. FIG. 24 illustrates thetransmission assembly 560 in the first drive position. In one form, thetransmission assembly 560 includes a locking assembly, generallydesignated as 590 that comprises a first or proximal lock lug portion592 and a second or distal lock lug portion 594 on the transmissionassembly 560. As can be seen in that Figure, the transmission assembly560 is positioned such that the proximal lock lug portion 592 is inengagement with the proximal carrier bracket 574. When in that firstdrive position, the proximal lock lug portion 592 prevents the planetarygear assembly 570 from rotating as a unit with the sun gear 582.However, rotation of the sun gear 582 results in rotation of theplanetary gears 572. Rotation of the planetary gears 572 results inrotation of the ring gear assembly 575. Rotation of the ring gearassembly 575 results in rotation of the first drive gear 524 and thefirst drive shaft 522. Because the proximal carrier bracket 574 isprevented from rotating, the distal carrier bracket 573 is alsoprevented from rotating. Thus, the second drive shaft 544 is alsoprevented from rotating while the first drive shaft 522 is rotated. Aspring (not shown) may be employed to bias the solenoid 71 (and thetransmission assembly 560 attached thereto) into this “first driveposition”. When the clinician desires to actuate the second drive system40, the solenoid 71 may be actuated using the firing trigger asdescribed above to move the solenoid shaft 73 to the position shown inFIG. 25 . When the transmission assembly 560 is in that “second driveposition”, the distal lock lug portion 594 retainingly engages the ringgear assembly 575 to prevent rotation thereof. Thus, when the sun gear582 is rotated, the planetary gear carrier (i.e., the distal carrierbracket 573 and proximal carrier bracket 574) will also rotate. Theplanetary gears 572 will rotate within the fixed internal ring gear 576.Such rotary motion will be transferred to the second drive shaft 542while the first drive shaft 522 remains unactuated.

FIG. 28 illustrates another form of motor driven surgical instrument 610that may be identical to surgical instrument 10 except for thedifferences noted below. Those components of surgical instrument 610that are the same as the components in the surgical instrument 10described above will be designated with the same element numbers. As canbe seen in FIG. 28 , for example, the first drive shaft axis “FDA” isoffset from and parallel with or is substantially parallel with thesecond drive shaft axis “SDA”. This arrangement comprises a motor 680that has dual, independently actuatable motor shafts 681, 683. The motor680 may be controlled by a firing trigger arrangement of the varioustypes described herein, such that actuation of the firing trigger in onemanner causes the motor 680 to rotate the first motor shaft 681 andactuation of the firing trigger in another manner causes the motor 680to rotate the second motor shaft 683. In this arrangement, a first motorgear 682 is mounted on the first motor shaft 681 and is supported inmeshing engagement with an idler gear 646. Idler gear 646 is operablysupported in meshing engagement with a first drive gear 624 that ismounted to a first drive shaft 622 of a first drive system 620. Thus,actuation of the first motor shaft 681 will result in actuation of thefirst drive system 620. Likewise, a second motor gear 684 is mounted onthe second motor shaft 683 and is supported in meshing engagement with asecond drive gear 644 that is mounted on a second drive shaft 642 of asecond drive system 640. As such, actuation of the second motor shaft683 will result in the actuation of the second drive system 640.

FIG. 29 illustrates another form of motor driven surgical instrument 710that may be identical to surgical instrument 10 except for thedifferences noted below. Those components of surgical instrument 710that are the same as the components in the surgical instrument 10described above will be designated with the same element numbers. As canbe seen in FIG. 29 , for example, the first drive shaft axis “FDA” isoffset from and parallel with or is substantially parallel with thesecond drive shaft axis “SDA”. In this arrangement, first and seconddrive systems 720, 740 are powered by a motor 780 through a unique andnovel “shiftable” transmission assembly 760. The first drive system 720includes a first drive shaft 722 that has a first drive gear 724 keyedthereon or otherwise non-rotatably affixed thereto. Similarly, thesecond drive system 740 includes a second drive shaft 742 that has asecond drive gear 744 keyed thereon or otherwise non-rotatably thereto.The motor 780 includes a motor gear 782 that is non-rotatably attachedto the shaft 781 of the motor 780.

In the illustrated arrangement, a second motor 750 is employed to shiftthe transmission assembly 760 as will be discussed in further detailbelow. The second motor 750 may be controlled, for example, by thevarious firing trigger and switch arrangements disclosed herein. Thesecond motor 750 can be controlled in a manner similar to the way thatthe motor 7038 is controlled as described hereinbelow in connection withFIGS. 61, 63A, 63B, 64 . As can be seen in FIG. 29 , a first transferpulley 753 is keyed onto or otherwise non-rotatably affixed to the motorshaft 752. A first pivot shaft 754 is rotatably supported within thehousing 12 of the handle 14. The first pivot shaft defines a pivot axis“PA”. A second transfer pulley 755 is non-rotatably mounted on the firstpivot shaft 754 and a transfer belt 756 is mounted on the first andsecond transfer pulleys 753, 755. In one form, the shiftabletransmission assembly 760 includes a transfer link 762 that is attachedto the first pivot shaft 754. In addition, an idler shaft 763 isattached to the transfer link 762 which operably supports an idler gear764 thereon. The shiftable transmission assembly 760 is movable betweena first drive position and a second drive position. To move theshiftable transmission assembly 760 to the first drive position, theclinician actuates the second motor 750 to rotate the pivot shaft 763and idler gear 764 about pivot axis PA such that it is in meshingengagement with the motor gear 782 and the first drive gear 724. When inthat position, actuation of the motor 780 will then result in actuationof the first drive system 720. When the clinician desires to actuate thesecond drive system 740, the second motor 750 is actuated to rotate theidler gear 764 about pivot axis PA into meshing engagement with themotor gear 782 and the second drive gear 744. When in that position,actuation of motor 780 results in actuation of the second drive system740. One benefit that may be achieved with this arrangement is thatprecise gear orientation is not required. As the idler gear 764 swingsinto position, it may be rotating and automatically will find a matingtooth.

FIGS. 30-32 illustrate a unique and novel motor unit 800 that may bemounted within a housing of the types described herein. The motor unit800 may include a separate housing structure 801 that operably supportsa first motor 802 with a first motor shaft 803 that defines a firstdrive system 804. The motor unit 800 may include a second motor 805 witha second motor shaft 806 that defines a second drive system 807. As canbe seen in FIG. 8 , for example, the first drive shaft axis “FDA” isoffset from and parallel with or is substantially parallel with thesecond drive shaft axis “SDA”. The unit 800 may further include acontrol circuit board 808 which contacts 808A that operably interfacewith corresponding contacts on the circuit board mounted within theinstrument housing or otherwise supported therein and communicating withthe instrument's control system. The housing may further includeelectrical contacts 808B which are configured to operably interface withcorresponding electrical contacts on an end effector tool that iscoupled thereto.

As illustrated in FIG. 1 , the modular surgical system 2 may include avariety of different surgical end effector arrangements 1000, 2000, and3000 that may be used in connection with various surgical instrumentsdescribed herein. As will be discussed in further detail below, each ofthe end effectors 1000, 2000, 3000 include dual, separate “first andsecond end effector drive systems” that are adapted to operablyinterface with the first and second drive systems in the surgicalinstrument to receive control motions therefrom. The end effector drivesystems are each configured to linearly move corresponding end effectoractuator components from first or beginning linear positions to secondor ending linear positions in response to corresponding rotary motionsapplied to the end effector drive systems by the surgical instrument towhich the end effector is operably attached. The end effector actuatorcomponents apply linear actuation motions to various end effectorcomponents located in the end effector tool head portion in order toperform various surgical procedures. As will be discussed in furtherdetail below, the end effectors employ unique components and systems forassisting the clinician in coupling the first and second drive shafts ofthe surgical instrument with the corresponding drive shafts in the endeffector. Because the four drive shafts are essentially simultaneouslycoupled together, various coupling arrangements and control techniquesmay be employed to ensure that the shafts are in the correct positionsor “near correct positions” that will facilitate such simultaneouscoupling of the drive systems.

Referring now to FIG. 33 , one form of mechanical coupling system 50 maybe employed to facilitate the simultaneous removable and operablecoupling of the two drive systems in the surgical instrument to thecorresponding “driven” shafts in the end effectors. The coupling system50 may comprise male couplers that may be attached to the drive shaftsin the surgical instrument and corresponding female socket couplers thatare attached to the driven shafts in the surgical end effector. Forexample, FIG. 9 illustrates male couplers 51 attached to the first andsecond drive shafts 22, 42 by set screws 52. Referring again to FIG. 33, each of the male couplers 51 are configured to be drivingly receivedwithin corresponding female socket couplers 57 that may also be attachedto the driven shafts within the end effector. In one form, each malecoupler 51 includes at least three drive ribs 53 that are equally spacedaround a center portion 54 of the male coupler 51. In the illustratedembodiment, for example, five drive ribs 53 are equally spaced aroundthe center portion 54. Each drive rib 53 has a pointed distal end 55.Each drive rib 53 may be formed with somewhat rounded edges 56 tofacilitate easy insertion into corresponding socket grooves 58 withinthe female socket coupler 57. Each socket groove 58 has a taperedproximal entrance portion 59 to facilitate insertion of a correspondingdrive rib 53 therein. The pointed distal end 55 of each drive rib 53 inconjunction with the tapered entrance 59 of each socket groove 58 willaccommodate some misalignment between the male coupler 51 and itscorresponding female socket coupler 57 during the coupling process. Inaddition, the rounded edges 57 on the pointed distal end 55 also assistin the slidable insertion of the male coupler 51 into the correspondingfemale socket coupler 58.

In one form, at least one of the male couplers 51 is movably attached toits corresponding first or second drive shaft of the surgical instrumentor its corresponding first and second driven shaft of the surgical endeffector. More specifically, the male coupler 51 may be attached forradial, or angular, travel on the shaft for a “first predeterminedamount of radial travel” on the shaft. This may be accomplished forexample, by key and keyway arrangements that are sized relative to eachother to facilitate an amount of radial, or angular, travel of the malecoupler 51 on the shaft. Stated another way, for example, the shaft mayhave a key formed thereon or otherwise mounted thereto that is smallerthan a corresponding keyway formed in the male coupler 51 such that thekey may move within the keyway and establish a first predeterminedamount of radial travel. This first predetermined amount of radialtravel is preferably sufficient enough to back drive or forward drivethe coupler. For a male coupler 51 that has five ribs 53, for example,the first predetermined range of radial travel may be, for example, 5-37degrees. Some embodiments may exist where the first predetermined rangeof radial travel may be less than 5° and preferably not more than 4°,for example. Such range of radial, or angular, travel may be sufficientif, for example, the corresponding female socket coupler 57 was rigidlyaffixed to its corresponding drive shaft and otherwise was incapable ofany radial travel. However, if both the male and female couplers havethe ability to radially, or angularly, adjust, such range of radial, orangular, travel may be reduced by 50% to provide each coupler (malecoupler and corresponding female socket coupler) with a range of travelof about 3-16 degrees. The amount of radial, or angular, travel that afemale socket coupler 57 may move on its corresponding shaft may bereferred to herein as a “second predetermined amount of radial travel”.The female socket couplers 57 may also be attached to their respectivedrive shafts with a key and keyway arrangement as described above thatprovides the desired second predetermined amount of radial travel. Someembodiments may exist where the second range of predetermined radialtravel may be less than 5° and preferably not more than 4°, for example.

Various combinations and mounting arrangements of the male couplers andthe female socket couplers are contemplated. For example, one or both ofthe male couplers may be movably mounted to their respective driveshafts of the surgical instrument (or driven shafts of the surgical endeffector) in the various manners described herein. Likewise one or bothof the female socket couplers may be movably mounted to their respectivedriven shafts on the end effector (or drive shafts of the surgicalinstrument) in the various manners described herein. For example, a malecoupler on one of the first and second drive shafts may be movablymounted thereon. The other male coupler that is attached to the otherdrive shaft may be non-movably mounted thereto. The female socketcoupler on the driven shaft that corresponds to the movably mounted malecoupler may be non-movably attached to its driven shaft and the femalesocket coupler mounted on the other driven shaft that corresponds to thenon-movably mounted coupler may be movably mounted to its driven shaft.Thus, one of a male coupler and a female coupler socket of a “couplerpair” is movable. The term “coupler pair” refers to the male coupler andcorresponding female socket coupler that is configured to be coupledtogether to operably couple a drive shaft of the surgical instrument toits corresponding driven shaft of the end effector. In otherarrangements both the male coupler and female coupler socket of acoupler pair may both be movably coupled to their respective shafts.

Such coupler arrangements serve to provide a small amount of angularslack, for example, between the coupler components so that thecomponents may rotate slightly for sufficient alignment which willpermit simultaneous alignment of the coupler components attached to thetwo separate rotary drive trains. In addition, there may be a sufficientamount of backlash or slack provided in the drive trains to accommodatethe coupling process. Such backlash or slack may be provided by formingkeys/keyways into the gears, couplers and or mating shafts to facilitatesuch slight rotation of components. In addition, a switch arrangementmay be employed in connection with the various shiftable transmissionassemblies which may activate the motor to cause a slight rotation ofthe drive shafts for coupling purposes. This and other controltechniques may be employed to ensure that the drive shafts in thesurgical instruments are positioned in desired positions that facilitatetheir coupling with the corresponding drive shafts in the end effectors.The unique and novel mechanical coupling system 50 serves to providesome additional flexibility during the coupling process to enable thedrive shafts to be coupled together in the event that there is somemisalignment between the respective shafts. It will be understood thatalthough the various embodiments described herein illustrate the malecouplers 51 attached to the drive shafts within the surgical instrumentand the female socket couplers 58 attached to the end effector driveshafts, the male couplers 51 could be attached to the end effector driveshafts and the female socket couplers 58 could be attached to theinstrument drive shafts.

FIGS. 34-37 depict a surgical end effector 1000 that comprises asurgical cutting and fastening instrument of a type that is commonlyreferred to as an “open linear” stapler. Various forms of such openlinear stapling devices are disclosed in, for example, U.S. Pat. No.5,415,334, entitled SURGICAL STAPLER AND STAPLE CARTRIDGE and U.S. Pat.No. 8,561,870, entitled SURGICAL STAPLING INSTRUMENT, the entiredisclosures of each being hereby incorporated by reference herein. Theend effector 1000 comprises an end effector housing 1010 that may befabricated from housing segments 1012, 1014 that are removably coupledtogether by screws, lugs, snap features, etc. Protruding from the endeffector housing 1010 are a lower jaw 1020 and an upper jaw 1040 whichmay collectively form the end effector tool head 1004. The lower jaw1020 comprises a lower jaw frame 1022 that is configured to operablysupport a surgical staple cartridge 1060 therein. Such surgical staplecartridges are well known in the art and will therefor not be describedin great detail herein. Briefly, the surgical staple cartridge 1060 maycomprise a cartridge body 1062 that has lines of staple pockets 1066formed therein on each lateral side of an elongate slot 1068 that iscentrally disposed within cartridge body 1062. The slot 1068 isconfigured to accommodate the longitudinal travel of a cutting member1090 therethrough as will be discussed in further detail below. Asurgical staple or staples (not shown) are supported in the staplepockets 1066 on staple drive members (not shown) that are configured tomove upward within their respective pocket 1066 during a firing process.The staple cartridge 1060 may be configured to be removed from the lowerjaw frame 1022 and replaced with another unspent cartridge making theend effector 1000 reusable. However, the end effector 1000 may also bedisposable after a single use.

Referring to FIG. 36 , the lower jaw frame 1022 may be formed from metalmaterial and have a U-shaped distal portion 1024 that is configured toseatingly receive the surgical staple cartridge 1060 therein. The sidewalls 1026 of the U-shaped distal portion 1024 may have a distal end1028 that is configured to releasably and retainingly engage a portionof the surgical cartridge 1060. The staple cartridge body 1062 may alsohave engagement features 1064 that are adapted to releasably engageupstanding wall portions 1030 of the lower jaw frame 1022. The endeffector 1000 further comprises an upper jaw 1040 that includes an anvilportion 1042. The anvil portion 1042 may include an underside (notshown) that has a plurality of staple-forming pockets therein. The upperjaw 1040 further includes a proximal body portion 1044 that has a distaltrunnion pin 1046 extending therethrough. The ends of the distaltrunnion pin 1046 that protrude laterally from the proximal end of theproximal body portion 1044 are rotatably received within trunnion holes1032 in the lower jaw 1020. The trunnion pin 1046 defines an attachmentaxis AA-AA about which the proximal end of the upper jaw 1040 pivotsrelative to the lower jaw 1020 such that the anvil portion 1042 ismovable between an open position spaced from the staple cartridge 1060mounted within the lower jaw 1020 and a closed position adjacent thestaple cartridge 1060 and/or tissue that is located therebetween. Theend effector 1000 may further include a transverse fulcrum pin 1050 thatis received within cradles 1034 formed in the upstanding walls 1030 ofthe lower jaw 1020 and is mounted within holes 1016 in the housingsegments 1012, 1014. The fulcrum pin 1050 may serve as a fulcrum axis orsurface about which the anvil portion 1042 pivots.

The movement of the anvil portion 1042 between the open and closedpositions is controlled by a first end effector drive system alsoreferred to herein as the end effector closure system 1070. In one form,for example, the end effector closure system 1070 includes a closureshuttle 1072 that extends around the proximal body portion 1024 of thelower jaw 1020. The closure shuttle 1072 may also be referred to as a“first end effector actuator”. The closure shuttle 1072 may include aU-shape portion that includes distal upstanding walls 1074 and proximalupstanding walls 1076. Each distal upstanding wall 1074 includes anarcuate cam slot 1078 that is adapted to receive a corresponding portionof a cam pin 1048 that is attached to the upper jaw 1040. Thus, axial orlinear movement of the closure shuttle 1072 relative to the lower jaw1020 will cause the upper jaw 1040 to pivot on the fulcrum pin 1050 andabout the attachment axis AA-AA by virtue of the interaction of the campin 1048 within the cam slots 1078.

In various forms, the closure system 1070 includes a rotary end effectorclosure shaft 1080 that is threaded and includes a distal end portion1082 that is rotatably supported within the end effector housing 1010.The end effector closure shaft 1080 defines a closure shaft axisCSA-CSA. See FIG. 37 . A female socket coupler 57 is attached to theproximal end of the closure shaft 1080 to facilitate coupling of theclosure shaft 1080 with a male coupler 51 attached to a first driveshaft in a surgical instrument. The closure system 1070 further includesa closure nut 1084 that is threadably received on the closure shaft1080. The closure nut 1084 is configured to be seated within mountingslots 1077 in the upstanding walls 1076 of the closure shuttle 1072.Thus, rotation of the closure shaft 1080 in a first direction will causethe closure nut 1084 to drive the closure shuttle 1072 in the distaldirection “DD”. Movement of the closure shuttle 1072 in the distaldirection “DD” results in the pivotal travel of the upper jaw 1040 froman open position to a closed position. Likewise, movement of the closureshuttle 1084 in the proximal direction “PD” will result in the movementof the upper jaw 1040 from a closed position back to an open position.

The end effector 1000 further includes a second end effector drivesystem also referred to herein as a firing system 1100 for driving atissue cutting member 1090 and wedge sled assembly 1092 between startingand ending positions. When the wedge sled assembly 1092 is drivendistally through the surgical staple cartridge 1060, the wedge sledassembly 1092 operably interacts with the drivers within the cartridge1060 that have surgical staples supported thereon. As the wedge sledassembly 1092 is driven distally, the drivers are driven upward withintheir respective pockets to drive the staples supported thereon intoforming engagement with the underside of the anvil portion 1042 of theupper jaw 1040. In one form, the firing system 1100 further includes arotary threaded firing shaft 1102 that is rotatably supported in the endeffector housing 1010. The firing shaft 1102 defines a firing shaft axisFSA-FSA that is parallel with or substantially parallel with the closureshaft axis CSA-CSA. See, e.g., FIG. 37 . The firing shaft 1102 includesa distal end portion 1104 that is rotatably supported in a mounting unit1106 that is mounted within the end effector housing 1010. A femalesocket coupler 57 is attached to the proximal end of the firing shaft1102 to facilitate coupling of the firing shaft 1102 with a male closurecoupler 51 that is attached to a second drive shaft in a surgicalinstrument. The firing system 1100 further includes a firing nut 1110that is threadably received on the firing shaft 1102. Thus, rotation ofthe firing shaft 1102 results in the axial travel of the firing nut 1110within the end effector housing 1010. In one form, the tissue cuttingmember 1090 and wedge sled assembly 1092 are coupled to the firing nut1110 by a firing bar or firing bars 1112. The firing bar or bars mayalso be referred to herein as a “second end effector actuator” that islinearly or axially moved in response to actuation of the firing system.Thus, rotation of the firing shaft 1102 in a first direction will drivethe firing nut 1110, firing bar(s) 1112, the tissue cutting member 1090and the wedge sled assembly 1092 in the distal direction “DD” from, forexample, a starting position (FIG. 35 ) to an ending position whereinthe tissue cutting member 1090 and wedge sled assembly 1092 have beendriven to the distal end of the surgical staple cartridge 1060. Rotationof the firing shaft 1102 in an opposite direction will drive the firingnut 1110, the firing bar(s) 1112, the tissue cutting member 1090 and thewedge sled assembly 1092 in a proximal direction “PD” from theirrespective ending positions back to their respective starting positions.In some embodiments, the wedge sled assembly may remain at the distalend of the surgical staple cartridge and not return with the tissuecutting member 1090 to the starting position. In still otherembodiments, the tissue cutting member and the wedge sled assemblymember may remain at the distal end of the staple cartridge member.

The end effector 1000 may also be equipped with various sensors that arecoupled to an end effector contact board 1120 mounted within the endeffector housing 1010. The contact board 1120 may be positioned with theend effector housing 1020 such that when the end effector 1000 isoperably coupled to the surgical instrument, the end effector contactboard 1120 is electrically coupled to a surgical instrument contactboard 30 mounted in the surgical instrument housing 12. See, e.g., FIG.1 . Referring again to FIG. 34 , a closure sensor 1122 may be mountedwithin the end effector housing 1010 and be electrically coupled to theend effector contact board 1120 such that when the end effector 1000 isoperably coupled to the surgical instrument, the closure sensor 1122 isin communication with the surgical instrument's control system. Theclosure sensor 1122 may comprise a Hall effect sensor 7028 as shownhereinbelow, for example, in connection with FIGS. 61, 63A, 63B that isconfigured to detect the position of a switch lug 1086 on the closurenut 1084. In addition, a firing sensor 1124 may also be mounted withinthe end effector housing 1010 to detect the presence of a firing bar1112. The firing sensor 1112 may comprise a Hall effect sensor 7028 asshown hereinbelow, for example, in connection with FIGS. 61, 63A, 63B,and be electrically coupled to the end effector contact board 1120 forultimate communication with the surgical instrument control system, suchas the handle processor 7024 as will be discussed in further detailbelow in connection with FIGS. 61, 63A, 63B, 64 .

Use of the end effector 1000 will now be explained in connection withsurgical instrument 10. It will be appreciated, however, that the endeffector 1000 may be operably coupled to various other surgicalinstrument arrangements disclosed herein. Prior to use, the closureshaft 1080 and the firing shaft 1102 are “clocked” or positioned intheir respective starting positions to facilitate attachment to thefirst and second drive shafts 22, 42, respectively. To couple the endeffector 1000 to the surgical instrument 10, for example, the clinicianmoves the end effector 1000 into a position wherein the closure shaftaxis CA-CA is in axial alignment with the first drive shaft axis FDA-FDAand wherein the firing shaft axis FSA-FSA is in axial alignment with thesecond drive shaft axis SDA-SDA. The female socket coupler 57 on theclosure shaft 1080 is inserted into operable engagement with the malecoupler 51 on the first drive shaft 22. Likewise, the female socketcoupler 57 on the firing shaft 1102 is inserted into operable engagementwith the male coupler 51 on the second drive shaft 42. Thus, when inthat position, the closure shaft 1080 is operably coupled to the firstdrive shaft 22 and the firing shaft 1102 is operably coupled to thesecond drive shaft 42. The end effector contact board 1120 is operablycoupled to the surgical instrument contact board 30 so that the sensors1122, 1124 (and any other sensors within the end effector 1000) are inoperable communication with the surgical instrument's control system. Toretain the end effector 1000 in coupled operable engagement with thesurgical instrument 10, the end effector 1000 includes a retainer latch1130 that is attached to the end effector housing 1010 and configured toreleasably engage a portion of the instrument housing 12. The retainerlatch 1130 may include a retention lug 1132 that may releasable engage aretainer cavity 15 formed in the housing 12. See FIG. 1 .

When coupled together, the closure sensor 1122 detects the position ofthe closure nut 1084 and the firing sensor 1124 detects the position ofthe firing bar 1112. That information is communicated to the surgicalinstrument control system. In addition, the clinician may confirm thatthe shiftable transmission assembly (or the transmission carriage 62thereof) is in its first drive position. This may be confirmed by theactuation of the indicator light 77 on the housing 12 as discussedabove. If the shiftable transmission assembly 60 is not in its firstdrive position, the clinician may actuate the firing trigger 92 to movethe transmission carriage 62 into the first drive position, such thatactuation of the rocker trigger 110 to actuate the motor 80 will resultin actuation of the first drive system 20. Assuming that the closuresystem 1070 and firing system 1100 are each in their respective startingpositions and the end effector 1000 has an unspent staple cartridge 1060properly installed therein, the clinician can then position the jaws1020, 1040 relative to the target tissue to be cut and stapled. Theclinician may close the upper jaw 1040 by actuating the rocker trigger110 to actuate the motor 80 and rotate the first drive shaft 22. Oncethe target tissue has been clamped between the upper jaw 1040 and thesurgical staple cartridge 1060 in the lower jaw 1020, the clinician maythen actuate the firing trigger 92 to move the transmission carriage 62to its second drive position such that actuation of the motor 80 willresult in the rotation of the second drive shaft 42. Once thetransmission carriage 62 is moved to the second drive position, theclinician may once again actuate the rocker trigger 110 to actuate thesecond drive system 40 and the firing system 1100 in the end effector1000 to drive the tissue cutting member 1090 and wedge sled assembly1092 distally through the surgical staple cartridge 1060. As the tissuecutting member 1090 and wedge sled assembly 1092 are driven distally,the target tissue clamped between the jaws 1020, 1040 is cut andstapled. Once the tissue cutting member 1090 and wedge sled assembly1092 have been driven to their distal-most positions in the surgicalstaple cartridge 1060, the clinician can actuate the rocker trigger 110to reverse the motor rotation and return the firing system 1100 to itsstarting position.

When employing end effector 1000 and other end effector and surgicalinstruments disclosed herein containing similar jaw arrangements it canbe challenging to adequately clean the anvil pockets in the underside ofthe anvil. In addition, the anvil pockets can gall, scive or simply wearover time making them ill-suited for reuse. Furthermore, depending uponthe application, loading and removing of the surgical staple cartridgemay be difficult. FIGS. 119-121 illustrate a single-use “staple pack”1300 that may address some, if not all, of these challenges.

FIG. 119 depicts a portion of an end effector 1000′ that may be similarin construction and operation to, for example, end effector 1000 as wellas other end effectors disclosed herein except for the specificdifferences discussed below. As can be seen in FIG. 119 , the upper jaw1240 includes an open distal end 1243. The upper jaw 1240 may be formedform metal material and have a U-shaped configuration when viewed fromthe distal end and include two-inwardly-extending, opposed retentionlips 1245. The end effector 1000′ further includes a lower jaw frame1222 that is similar to, for example, lower jaw frame 1222 describedherein. As can be seen in that Figure, the lower jaw fame 1222 also hasan open distal end 1223.

Still referring to FIG. 119 , one form of “single-use” staple pack 1300includes an anvil 1302 that has a staple-forming surface 1304 thatincludes a plurality of staple-forming pockets (not shown) that areformed therein. The staple pack 1300 further includes a staple cartridge1310 that has a cartridge deck 1312 that is configured for spacedconfronting relationship to the staple-forming undersurface 1304 of theanvil 1302. The staple cartridge 1310 may be similar to other staplecartridges disclosed in further detail herein and operably support aplurality of surgical staples therein. The staple pack 1300 furtherincludes a disposable keeper member 1320 that is sized and shaped tofrictionally engage the anvil 1302 and staple cartridge 1310 in such amanner as to maintain alignment between the staple pockets in thestaple-forming undersurface 1304 and the staples (not shown) within thestaple cartridge 1310 prior to use. The keeper 1320 may also include aspacer strip 1322 that extends between the anvil 1302 and the staplecartridge 1310. The keeper may, for example, be molded from plastic orother suitable polymer material and the spacer strip 1322 may befabricated from metal material. The spacer strip 1322 may befrictionally retained in a slot or other retention feature formed in thekeeper 1320.

Referring now to FIG. 120 , the staple pack 1300 is installed byaligning the anvil 1302 with the open distal end 1243 in the upper jaw1240 and the staple cartridge 1310 is aligned with the open distal end1245 in the lower jaw frame 1222. Thereafter, the staple pack 1300 ismoved in the proximal direction “PD” to the position illustrated in FIG.120 . The retention lips 1245 serve to support the anvil 1302 within theupper jaw 1240. The end effector 1000′ may also include a manuallyactuatable latch feature 1340 that may be moved from an unlatchedposition (FIG. 119 ) to a latched position (FIG. 121 ). When in thelatched position, for example, the latch feature 1340 retains the anvil1302 within the upper jaw 1240 and the staple cartridge 1310 within thelower jaw frame 1222. For example, the latch feature 1340 may include amovable upper latch arm 1342 that is configured to releasably engage aportion (e.g., lip, detent, ledge or other retention feature(s)) formedon the proximal end of the anvil 1302. Similarly the latch feature 1340may include a movable lower latch arm 1344 that is configured toreleasably engage a portion (e.g., lip, detent, ledge or other retentionfeature(s)) formed on the staple cartridge 1310. The upper and lowerlatch arms 1342, 1344 may be pivotally or otherwise movably supported onthe end effector 1000′ for selective movement between the latched andunlatched positions. In various forms the upper and lower latch arms1342, 1344 may be normally biased into the latched position by a springor springs (not shown). In such arrangements, the clinician may insertthe staple pack 1300 into the upper jaw 1240 and lower jaw frame 1222.As the proximal end of the anvil 1302 contacts the upper latch arm 1342,the upper latch arm 1342 is pivoted or moved to permit the anvil 1302 tobe seated into position. Once the anvil is seated in position, the upperlatch arm 1342 is biased into latching engagement with the anvil 1302(if a spring or biasing member is employed). In alternativearrangements, the upper latch arm 1342 may be manually moved into thelatched position. Likewise, as the proximal end of the staple cartridge1310 contacts the lower latch arm 1344, the lower latch arm 1344 ispivoted or moved to permit the staple cartridge 1310 to be seated intoposition. Once the staple cartridge 1310 is seated in position, thelower latch arm 1344 is biased into latching engagement with the staplecartridge 1310 to retain it in position (if a spring or biasingarrangement is employed). In alternative embodiments, the lower latcharm 1344 may be manually moved to the latched position. Once the staplepack 1300 has been installed and the anvil 1302 and staple cartridge1310 have been latched or otherwise attached to the end effector 1000′,the clinician may remove the keeper assembly 1320. See, e.g., FIG. 121 .After the staple pack 1300 has been used, the clinician may then replacethe keeper 1320 onto the distal ends of the anvil 1302 and the staplecartridge 1310. This may be accomplished by aligning the open end of thekeeper member 1320 and then pressing the keeper member 1320 back intofrictional engagement with the anvil 1302 and staple cartridge 1310.Once the distal ends of the anvil 1302 and staple cartridge 1310 havebeen seated into the keeper member 1320, the clinician may move theupper and lower latch arms 1342, 1344 to their an unlatched positions toenable the staple pack 1300 to be pulled out of the upper jaw 1240 andlower jaw frame 1222. Thereafter, the staple pack 1300 may be discardedas a unit. In other situations, the clinician may separately remove theanvil 1302 and staple cartridge 1310 from the end effector 1000′ withoutfirst installing the keeper member 1320.

FIGS. 38-41 depict a surgical end effector 2000 that comprises asurgical cutting and fastening instrument of a type that may commonly bereferred to as a “curved cutter stapler”. Various forms of such staplingdevices are disclosed in, for example, U.S. Pat. No. 6,988,650, entitledRETAINING PIN LEVER ADVANCEMENT MECHANISM FOR A CURVED CUTTER STAPLERand U.S. Pat. No. 7,134,587, entitled KNIFE RETRACTION ARM FOR A CURVEDCUTTER STAPLER the entire disclosures of each being hereby incorporatedby reference herein. The end effector 2000 comprises an end effectorhousing 2010 that may be fabricated from housing segments 2012, 2014that are removably coupled together by screws, lugs, snap features, etc.Protruding from the end effector housing 2010 is an elongated frameassembly 2020 that terminates in an end effector tool head 2002. In oneform, the frame assembly 2020 comprises a pair of spaced frame struts orplates 2022 that are fixedly attached to the housing 2010 and protrudedistally therefrom. A C-shaped supporting structure 2024 is attached tothe distal end of the frame plates 2022. The term “C-shaped” is usedthroughout the specification to describe the concave nature of thesupporting structure 2024 and a surgical cartridge module 2060. TheC-shaped construction facilitates enhanced functionality and the use ofthe term C-shaped in the present specification should be construed toinclude a variety of concave shapes which would similarly enhance thefunctionality of surgical stapling and cutting instruments. Thesupporting structure 2024 is attached to the frame plates 2022 by ashoulder rivet 2023 and posts 2026 which extend from the supportingstructure 2024 into receiving holes in the frame plates 2022. In variousforms, the supporting structure 2024 may be formed via a single piececonstruction. More specifically, the supporting structure 2024 may beformed from extruded aluminum material. By forming the supportingstructure 2024 in this manner, multiple parts are not required and theassociated cost of manufacture and assembly is substantially reduced. Inaddition, it is believed the unitary structure of the supportingstructure 2024 enhances the overall stability of the end effector 2000.Furthermore, the unitary extruded structure of the supporting structure2024 provides for a reduction in weight, easier sterilization sincecobalt irradiation will effectively penetrate the extruded aluminum andless trauma to tissue based upon the smooth outer surface achieved viaextrusion.

The end effector 2000 further includes a first end effector drive systemalso referred to as end effector closure system 2070 and a second endeffector drive system also referred to herein as a firing system 2100.In one form, for example, the end effector closure system 2070 includesa closure beam assembly 2072 that is sized to be slidably receivedbetween the frame struts 2022 for axial travel therebetween. The closurebeam assembly 2072 may also be referred to as a first end effectoractuator and has an open bottom configured to slidably receive a firingbar assembly 2112 of the firing system 2100 as will be discussed infurther detail below. In one form, for example, the closure beamassembly 2072 is a molded plastic member shaped for movement andfunctionality as will be further discussed below. By manufacturing theclosure beam assembly 2072 from plastic, manufacturing costs may bereduced and the weight of the end effector 2000 may also be reduced. Inaddition, the end effector 2000 may be easier to sterilize with cobaltirradiation as plastic is easier to penetrate than stainless steel. Inaccordance with an alternate arrangement, the closure beam assembly 2072may be made from extruded aluminum with the final features machined intoplace. While an extruded aluminum closure beam assembly might not be aseasy to manufacture as the plastic component, it would still have thesame advantages (i.e., elimination of components, easier to assemble,lower weight, easier to sterilize).

The closure beam assembly 2072 includes a curved distal end 2074 that issized to be received between the side walls 2027 of the supportingstructure 2024. The curved distal end 2074 is sized and shaped toreceive and retain a cartridge housing 2062 of the cartridge module2060. In various forms, the proximal end of the closure beam assembly2072 is coupled to a closure nut 2084 that is threadably received on athreaded closure shaft 2080. The closure shaft 2080 defines a closureshaft axis CSA-CSA and has a female socket coupler 57 is attached to itsproximal end to facilitate coupling of the closure shaft 2080 with amale coupler 51 attached to a first drive shaft in a surgicalinstrument. Rotation of the closure shaft 2080 in a first direction willcause the closure nut 2084 to drive the closure beam assembly 2072 inthe distal direction “DD”. Rotation of the closure shaft 2080 in anopposite direction will likewise result in the proximal travel of theclosure nut 2084 and the closure beam assembly 2072.

As indicated above, the distal end 2074 of the closure beam assembly2072 is configured to operably support the cartridge housing 2062 of acartridge module 2060 therein. The cartridge module 2060 includes aplurality of surgical staples (not shown) on a staple driver (not shown)that, when axially advanced, drives the surgical staples out of theirrespective pockets 2066 positioned on each side of a slot 1068 that isconfigured to accommodate the passage of a knife member 2115therethrough. The cartridge module 2060 may, for example, be somewhatsimilar to the cartridge modules disclosed in, for example, U.S. Pat.Nos. 6,988,650 and 7,134,587, which have both been incorporated byreference in their respective entireties herein excepted for any noteddifferences. The end effector 2000 may be disposed of after a single useor the end effector 2000 may be reusable by replacing the spentcartridge module during an ongoing procedure or for a new procedureafter being resterilized.

The end effector 2000 further includes a firing system 2100 whichincludes a firing bar assembly 2112 that is configured to be slidablyreceived within the open bottom of the closure beam assembly 2072. SeeFIG. 39 . In one form, the firing system 2100 further includes a firingshaft 2102 that has a threaded distal end 2104 and a proximal portion2106 that has a square cross-sectional shape. The threaded distal end2104 is threadably received within a threaded firing nut 2110 that isattached to the proximal end of the firing bar assembly 2112. Thethreaded firing nut 2110 is sized to be slidably received within anaxial cavity 2085 within the closure nut assembly 2084. See FIG. 41 .Such arrangement permits the firing nut 2110 to be axially advanced withthe closure nut assembly 2084 when the end effector 2000 is moved to aclosed position and then move axially relative to the closure nut 2084and closure beam assembly 2072 when the firing system 2100 is actuated.The firing shaft 2102 defines a firing shaft axis FSA-FSA that isparallel with or substantially parallel with the closure shaft axisCSA-CSA. See, e.g., FIG. 41 . As can also be seen in FIGS. 39 and 41 ,the proximal portion 2106 of the firing shaft 2102 is slidably receivedwithin an elongated passage 2105 within a female socket coupler 57′ thatis otherwise identical to the female socket couplers described herein.The elongated passage 2105 has a square cross-sectional shape that issized to slidably receive the proximal portion 2106 of the firing shaft2102 therein. Such arrangement permits the firing shaft 2102 to moveaxially relative to the female socket coupler 57′ while being rotatablewith the female socket coupler 57′. Thus, when the closure beam assembly2072 is advanced in the distal direction “DD” upon actuation of thefirst drive system in the surgical instrument, the firing nut 2110 willbe carried in the distal direction “DD” within the closure nut assembly2084. The proximal portion 2106 of the firing shaft 2102 will moveaxially within the passage 2105 in the female socket coupler 57′ whileremaining engaged therewith. Thereafter, activation of the second drivesystem in one rotary direction in the surgical instrument which isoperably coupled to the female socket coupler 57′ will rotate the firingshaft 2102 which will cause the firing bar assembly 2112 to move in thedistal direction “DD”. As the firing bar assembly 2112 moves in thedistal direction, the knife bar 2115 is advanced distally through thecartridge module 2060. Actuation of the second drive system in a secondrotary direction will cause the firing bar assembly 2112 to move in theproximal direction “PD”.

The distal end of the firing bar assembly 2112 includes a drive member2114 and the knife member 2115 that protrudes distally therefrom. As canbe seen in FIG. 39 , the knife member 2115 is slidably received withinan anvil arm portion 2142 of an anvil assembly 2140 that is configuredto be seated within a curved anvil support portion 2025 of the supportstructure 2024. Further details regarding the anvil assembly 2140 may befound in U.S. Pat. Nos. 6,988,650 and 7,134,587. The end effector 2000may also include a safety lockout mechanism 2150 (FIG. 39 ) forpreventing the firing of a previously fired cartridge module 2060.Details regarding the interaction between the cartridge module 2060 andthe safety lockout mechanism may be found in U.S. Pat. Nos. 6,988,650and 7,134,587.

The end effector 2000 also includes a tissue retaining pin actuationmechanism 2160. The tissue retaining pin actuation mechanism 2160includes a saddle shaped slide 2162 that is positioned on a top portionof the housing 2010. The slide 2162 is pivotally connected to a push roddriver 2163 that is slidably supported within the housing 2010. The pushrod driver 2163 is restrained for longitudinal movement along the longaxis of the end effector 2000. The push rod driver 2163 is connected toa push rod 2164 by a circumferential groove 2165 on the push rod 2164that snaps into a slot 2166 of the push rod driver 2163. See FIG. 41 .The distal end of the push rod 2164 contains a circumferential groove2167 that interconnects with a groove 2172 in a proximal end of acoupler 2170 that is attached to the cartridge module 2160 (best seen inFIG. 41 ). The distal end of the coupler 2170 contains a groove 2174 forinterconnecting with a circumferential slot 2182 on a retaining pin2180. Manual movement of the slide 2162 results in movement of the pushrod 2164. The distal movement or proximal retraction of the push rod2164 results in corresponding movement of the retaining pin 2180. Theretaining pin 2180 actuation mechanism 2160 also operably interacts withthe closure beam assembly 2072 such that actuation of the closure system2070 will result in automatic distal movement of the retaining pin 2180if it has not already been manually moved to its most proximal position.When the retaining pin 2180 is advanced, it extends through thecartridge housing 2062 and into the anvil assembly 2140 to therebycapture tissue between the cartridge module 2060 and the anvil assembly2140.

In one form, the retaining pin actuation mechanism 2160 includes a yoke2190 rotationally or pivotally supported within the housing 2010 via apivot pin 2192. The closure beam assembly 2072 further includes posts orlugs 2073 which extend laterally on both sides of the closure beamassembly 2072 inside the housing 2010. These posts 2073 are slidablyreceived within corresponding arcuate slots 2194 in the yoke 2190. Theyoke 2190 contains cam pins 2196 positioned to push camming surfaces2168 on the push rod driver 2163. The yoke 2190 is not directly attachedto the retaining pin 2180 so the surgeon, if they chose, can advance theretaining pin 2180 manually. The retaining pin 2180 will advanceautomatically if the surgeon chooses to leave the retaining pin 2180alone when the closure beam assembly 2072 is advanced distally to aclosed position. The surgeon must retract the retaining pin 2180manually. By constructing the retaining pin actuation mechanism 2160 inthis manner, manual closing and retracting of the retaining pin 2180 ispermitted. If the surgeon does not manually close the retaining pin21280, the present retaining pin actuation mechanism 2160 will do itautomatically during instrument clamping. Further details regardingactuation and use of the retaining pin may be found in U.S. Pat. Nos.6,988,650 and 7,134,587.

The end effector 2000 may also be equipped with various sensors that arecoupled to an end effector contact board 2120 mounted within the endeffector housing 2010. For example, the end effector 2000 may include aclosure sensor 2122 that is mounted within the end effector housing 2010and is electrically coupled to the end effector contact board 2120 suchthat when the end effector 2000 is operably coupled to the surgicalinstrument, the closure sensor 2122 is in communication with thesurgical instrument's control system. The closure sensor 2122 maycomprise a Hall effect sensor 7028 as shown hereinbelow in connectionwith FIGS. 61, 63A, 63B that is configured to detect the position of aswitch lug 2086 on the closure nut 21084. See FIG. 40 . In addition, afiring sensor 2124 may also be mounted within the end effector housing2010 and be arranged to detect the location of the firing nut 2110within the closure nut 2084. The firing sensor 2124 may comprise a Halleffect sensor 7028 as described hereinbelow in connection with FIGS. 61,63A, 63B and be electrically coupled to the end effector contact board2120 for ultimate communication with the surgical instrument controlsystem as discussed herein. The contact board 2120 may be positionedwith the end effector housing 2020 such that when the end effector 2000is operably coupled to the surgical instrument, the end effector contactboard 2120 is electrically coupled to a surgical instrument contactboard 30 mounted in the surgical instrument housing 12 as was discussedabove.

Use of the end effector 2000 will now be explained in connection withsurgical instrument 10. It will be appreciated, however, that the endeffector 2000 may be operably coupled to various other surgicalinstrument arrangements disclosed herein. Prior to use, the closureshaft 2080 and the firing shaft 2102 are “clocked” or positioned intheir starting positions to facilitate attachment to the first andsecond drive shafts 22, 42, respectively. To couple the end effector2000 to the surgical instrument 10, for example, the clinician moves theend effector 2000 into a position wherein the closure shaft axis CSA-CSAis in axial alignment with the first drive shaft axis FDA-FDA andwherein the firing shaft axis FSA-FSA is in axial alignment with thesecond drive shaft axis SDA-SDA. The female socket coupler 57 on theclosure shaft 2080 is inserted into operable engagement with the malecoupler 51 on the first drive shaft 22. Likewise, the female socketcoupler 57′ on the firing shaft 2102 is inserted into operableengagement with the male coupler 51 on the second drive shaft 42. Thus,when in that position, the closure shaft 2080 is operably coupled to thefirst drive shaft 22 and the firing shaft 2102 is operably coupled tothe second drive shaft 42. The end effector contact board 1120 isoperably coupled to the surgical instrument contact board 30 so that thesensors within the end effector 2000 are in operable communication withthe surgical instrument's control system. To retain the end effector2000 in coupled operable engagement with the surgical instrument 10, theend effector 2000 includes a retainer latch 2130 that is attached to theend effector housing 2010 and is configured to releasably engage aportion of the instrument housing 12. The retainer latch 2130 mayinclude a retention lug 2132 that may releasable engage a retainercavity 15 formed in the housing 12. See FIG. 1 . When coupled together,the closure sensor 2122 detects the position of the closure nut 2084 andthe firing sensor 2124 detects the position of the firing nut 2110. Thatinformation is communicated to the surgical instrument control system.In addition, the clinician may confirm that the shiftable transmissionassembly (or the transmission carriage 62 thereof) is in its first driveposition. This may be confirmed by the actuation of the indicator light77 on the housing 12 as was discussed above. If the shiftabletransmission assembly 60 is not in its first drive position, theclinician may actuate the firing trigger 92 to move the transmissioncarriage 62 into the first drive position, such that actuation of therocker trigger 110 to actuate the motor 80 will result in actuation ofthe first drive system 20. Assuming that the closure system 2070 andfiring system 2100 are each in their respective starting positions andthe end effector 2000 has an unspent staple cartridge module 2060properly installed therein, the clinician can then actuate the closuresystem 2070 to capture the target tissue between the cartridge module2060 and the anvil assembly 2140.

The clinician may move the closure beam assembly 2072 distally byactuating the rocker trigger 110 to actuate the motor 80 and rotate thefirst drive shaft 22. This actuation moves the cartridge module 2060toward the anvil assembly 2140 to clamp the target tissue therebetween.As the closure beam 2072 moves distally, the interaction of the posts2073 and the yoke 2190 will cause actuation of the tissue retainingactuation mechanism 2160 to drive the retaining pin 2180 distallythrough the deck portion 2161 and through the anvil assembly 2140 into apin pocket 2141 (See FIG. 41 ) therein. The retaining pin 2180 serves totrap the target tissue between the anvil assembly 2140 and the cartridgemodule 2060. Once the target tissue has been clamped between the anvilassembly 2140 and the cartridge module 2060, the clinician may thenactuate the firing trigger 92 to move the transmission carriage 62 toits second drive position such that actuation of the motor 80 willresult in the rotation of the second drive shaft 42. Once thetransmission carriage 62 is moved to the second drive position, theclinician may once again actuate the rocker trigger 110 to actuate thesecond drive system 40 and the firing system 2100 in the end effector2000 to drive the firing bar assembly 2112 distally which also drivesthe knife member 2115 distally through the cartridge module 2060 cuttingthe target tissue clamped between the anvil assembly 2140 and thecartridge module 2060. As the firing bar assembly 2112 moves distally,the drive member 2114 also drives the surgical staples supported in thecartridge module 2060 out of the cartridge module 2060 through thetarget tissue and into forming contact with the anvil assembly 2140.Once the cutting and stapling action is completed, the clinician canactuate the rocker trigger 110 to reverse the motor rotation and returnthe firing system 2100 to its starting position. The clinician may thenreturn the transmission carriage 62 to its first drive position by meansof the firing trigger 92 such that actuation of the rocker trigger 110in the opposite direction will cause the motor 80 to rotate in a reversedirection to return the closure beam assembly 2073 to its startingposition. As the closure beam assembly 2073 moves in the proximaldirection, the yoke 2190 may interact with the tissue retaining pinactuation mechanism 2160 to withdraw the retaining pin 2180 to itsstarting position. In the alternative, the clinician may manuallyretract the retention pin 2180 to its starting position using the saddleshaped slide 2162. The clinician may retract the retention pin 2180 toits starting position prior to actuating the closure system 2070 toreturn the closure beam 2072 to its starting position. Further detailsregarding use of curved staple cutters may be found in U.S. Pat. Nos.6,988,650 and 7,134,587.

FIGS. 42-45 depict a surgical end effector 3000 that comprises asurgical cutting and fastening instrument of a type that may commonly bereferred to as a “circular surgical stapler”. In certain types ofsurgical procedures, the use of surgical staples has become thepreferred method of joining tissue and, as such, specially configuredsurgical staplers have been developed for these applications. Forexample, intra-luminal or circular staplers have been developed for usein surgical procedures involving the lower colon wherein sections of thelower colon are joined together after a diseased portion has beenexcised. Circular staplers useful for performing such procedures aredisclosed, for example, in U.S. Pat. Nos. 5,104,025; 5,205,459;5,285,945; 5,309,927; 8,353,439; and 8,360,297 which are each hereinincorporated by reference in their respective entireties.

As shown in FIG. 42 , the end effector 3000 comprises an end effectorhousing 3010 that may be fabricated from housing segments 3012, 3014that are removably coupled together by screws, lugs, snap features, etc.Protruding from the end effector housing 3010 is an elongated shaftassembly 3020. The elongated shaft assembly 3020 is configured tooperably support and interact with a circular tool head 3300 and ananvil 3320. As evidenced by the exemplary U.S. patents referenced above,a variety of different circular staple cartridge and anvil arrangementsare known in the art. As shown in FIG. 43 , for example, the circularstapler head 3300 may include a casing member 3302 that supports acartridge supporting assembly in the form of a circular staple driverassembly 3304 therein that is adapted to interface with a circularstaple cartridge 3306 and drive staples supported therein into formingcontact with the staple forming undersurface 3326 of the anvil 3320. Acircular knife member 3308 is also centrally disposed within the stapledriver assembly 3304. The proximal end of the casing member 3302 may becoupled to an outer tubular shroud 3022 of the arcuate shaft assembly3020 by a distal ferrule member 3024. The anvil 3320 includes a circularbody portion 3322 that has an anvil shaft 3324 for attaching a trocarthereto. The anvil body 3322 has a staple forming undersurface 3326thereon and may also have a shroud 3328 attached to the distal endthereof. The anvil shaft 3324 may be further provided with a pair oftrocar retaining clips or leaf-type springs 3330 that serve toreleasably retain a trocar 3042 in retaining engagement with the anvilshaft 3324 as will be discussed in further detail below.

In one form, the shaft assembly 3020 includes a compression shaft 3030,a distal compression shaft portion 3032, and a tension band assembly3040 that are operably supported within the outer tubular shroud 3022. Atrocar tip 3042 is attached to a distal end of the tension band assembly3040 by fasteners 3041. As is known, the trocar tip 3042 may be insertedinto the anvil shaft 3324 of the anvil 3320 and retained in engagementby trocar retaining clips 3330.

The surgical end effector 3000 further includes a closure system 3070and a firing system 3100. In at least one form, the closure system 3070includes a closure nut assembly 3084 that is attached to the proximalend of the tension band 3040. As can be seen in FIGS. 42 and 43 , theclosure nut assembly 3084 includes a proximal coupler member 3085 thatis attached to the proximal end of the tension band 3040 by a fastener3087. The closure system 3070 further includes a threaded closure shaft3080 that is in threaded engagement with the closure nut 3084. Theclosure shaft 3080 defines a closure shaft axis CSA-CSA and has a femalesocket coupler 57 attached to its proximal end to facilitate coupling ofthe closure shaft 3080 with a male coupler 51 that is attached to afirst drive shaft in a surgical instrument. Rotation of the closureshaft 3080 in a first direction will cause the closure nut 3084 to drivethe tension band assembly 3040 in the distal direction “DD”. Rotation ofthe closure shaft 3080 in an opposite direction will likewise result inthe proximal travel of the closure nut 3084 and the tension bandassembly 3040.

As can be seen in FIG. 43 , the distal compression shaft portion 3032 iscoupled to the staple driver assembly 3304. Thus, axial movement of thecompression shaft 3030 within the outer tubular shroud 3022 causes thestaple driver assembly 3304 to move axially within the casing member3302. The axial travel of the compression shaft 3030 is controlled bythe firing system 3100. In one form, the firing system 3100 includes athreaded firing shaft 3102 that is in threaded engagement with athreaded firing nut 3110 that is attached to the proximal end of thecompression shaft 3030. The firing shaft 3102 defines a firing shaftaxis FSA-FSA that is parallel with or substantially parallel with theclosure shaft axis CSA-CSA. See, e.g., FIGS. 44 and 45 . The proximalend of the firing shaft 3102 has a female socket coupler 57 attachedthereto to facilitate coupling of the firing shaft 3102 with a malecoupler 51 that is attached to a second drive shaft in a surgicalinstrument. Activation of the second drive system of the surgicalinstrument in one rotary direction will rotate the firing shaft 3102 ina first direction to thereby drive the compression shaft 3030 in thedistal direction “DD”. As the compression shaft 3030 moves in the distaldirection “DD”, the circular staple driver assembly 3304 is drivendistally to drive the surgical staples in the staple cartridge 3306 intoforming contact with the underside 3326 of the anvil body 3322. Inaddition, the circular knife member 3308 is driven through the tissueclamped between the anvil body 3322 and the staple cartridge 3306.Actuation of the second drive system in a second rotary direction willcause the compression shaft 3030 to move in the proximal direction “PD”.

The end effector 3000 may also be equipped with various sensors that arecoupled to an end effector contact board 3120 mounted within the endeffector housing 3010. For example, the end effector 3000 may includeclosure sensor(s) 3122 that are mounted within the end effector housing3010 and are electrically coupled to the end effector contact board 3120such that when the end effector 3000 is operably coupled to the surgicalinstrument, the closure sensor(s) 3122 are in communication with thesurgical instrument's control system. The closure sensor(s) 3122 maycomprise Hall effect sensors 7028 as described hereinbelow in connectionwith FIGS. 61, 63A, 63B that are configured to detect the position ofthe closure nut 3084. See FIG. 44 . In addition, firing sensor(s) 3124may also be mounted within the end effector housing 3010 and be arrangedto detect the location of the firing nut 3110 within the closure nut3084. The firing sensor(s) 3124 also may comprise Hall effect sensors7028 as described hereinbelow in connection with FIGS. 61, 63A, 63B andbe electrically coupled to the end effector contact board 3120 forultimate communication with the surgical instrument control system, suchas the handle processor 7024, for example, as described in further belowin connection with FIGS. 61, 63A, 63B, 64 . The contact board 3120 maybe positioned with the end effector housing 3020 such that when the endeffector 3000 is operably coupled to the surgical instrument, the endeffector contact board 3120 is electrically coupled to a surgicalinstrument contact board 30 mounted in the surgical instrument housing12 as was discussed above.

Use of the end effector 3000 will now be explained in connection withsurgical instrument 10. It will be appreciated, however, that the endeffector 3000 may be operably coupled to various other surgicalinstrument arrangements disclosed herein. Prior to use, the closureshaft 3080 and the firing shaft 3102 are “clocked” or positioned intheir starting positions to facilitate attachment to the first andsecond drive shafts 22, 42, respectively. To couple the end effector3000 to the surgical instrument 10, for example, the clinician moves theend effector 3000 into a position wherein the closure shaft axis CSA-CSAis in axial alignment with the first drive shaft axis FDA-FDA andwherein the firing shaft axis FSA-FSA is in axial alignment with thesecond drive shaft axis SDA-SDA. The female socket coupler 57 on theclosure shaft 3080 is inserted into operable engagement with the malecoupler 51 on the first drive shaft 22. Likewise, the female socketcoupler 57 on the firing shaft 3102 is inserted into operable engagementwith the male coupler 51 on the second drive shaft 42. Thus, when inthat position, the closure shaft 3080 is operably coupled to the firstdrive shaft 22 and the firing shaft 3102 is operably coupled to thesecond drive shaft 42. The end effector contact board 3120 is operablycoupled to the surgical instrument contact board 30 so that the sensors3122, 3124 within the end effector 3000 are in operable communicationwith the surgical instrument's control system. To retain the endeffector 3000 in coupled operable engagement with the surgicalinstrument 10, the end effector 3000 includes a retainer latch 3130 thatis attached to the end effector housing 3010 and configured toreleasably engage a portion of the instrument housing 12. The retainerlatch 3130 may include a retention lug 3132 that may releasable engage aretainer cavity 15 formed in the housing 12. See FIG. 1 . When coupledtogether, the closure sensor 3122 detects the position of the closurenut 3084 and the firing sensor 3124 detects the position of the firingnut 3110. That information is communicated to the surgical instrumentcontrol system. In addition, the clinician may confirm that theshiftable transmission assembly (or the transmission carriage 62thereof) is in its first drive position. This may be confirmed by theactuation of the indicator light 77 on the housing 12 as was discussedabove. If the shiftable transmission assembly 60 is not in its firstdrive position, the clinician may actuate the firing trigger 92 to movethe transmission carriage 62 into the first drive position, such thatactuation of the rocker trigger 110 to actuate the motor 80 will resultin actuation of the first drive system 20. Assuming that the closuresystem 3070 and firing system 3100 are each in their respective startingpositions and the end effector 3000 has an unspent staple cartridgemodule properly installed therein, the end effector 3000 is ready foruse.

As is known, when performing an anastomosis using a circular stapler,the intestine may be stapled using a conventional surgical stapler withmultiple rows of staples being emplaced on either side of a targetsection (i.e., specimen) of the intestine. The target section istypically simultaneously cut as the section is stapled. After removingthe target specimen, the clinician inserts the anvil 3320 into theproximal portion of the intestine, proximal of the staple line. This maybe done by inserting the anvil body 3322 into an entry port cut into theproximal intestine portion or the anvil 3320 can be placed trans-anally,by placing the anvil 3320 on the distal end of the end effector 3000 andinserting the instrument through the rectum. Next, the clinicianattaches the anvil shaft 3324 to the trocar tip 3042 of the end effector3000 and inserts the anvil 3320 into the distal portion of theintestine. The clinician may then tie the distal end of the proximalsection of the intestine to the anvil shaft 3324 using a suture or otherconventional tying device and also tie the proximal end of the distalintestine portion around the anvil shaft 3324 using another suture.

The clinician may then move the tension band assembly 3040, trocar tip3042 and anvil 3320 attached thereto proximally by actuating the rockertrigger 110 to actuate the motor 80 and rotate the first drive shaft 22.This actuation moves the anvil 3320 toward the cartridge 3306 supportedin the casing member 3302 of the stapler head 3300 to close the gaptherebetween and thereby engages the proximal end of the distalintestine portion with the distal end of the proximal intestine portionin the gap therebetween. The clinician continues to actuate the firstdrive system 20 until a desired amount of tissue compression isattained. Once the intestine portions have been clamped between theanvil assembly 3320 and the stapler head 3300, the clinician may thenactuate the firing trigger 92 to move the transmission carriage 62 toits second drive position such that actuation of the motor 80 willresult in the rotation of the second drive shaft 42. Once thetransmission carriage 62 is moved to the second drive position, theclinician may once again actuate the rocker trigger 110 to actuate thesecond drive system 40 and the firing system 3100 in the end effector3000 to drive the compression shaft 3030 distally which also drives thecircular staple driver assembly 3304 and the circular knife member 3308distally. Such action serves to cut the clamped pieces of intestine anddrive the surgical staples through both clamped ends of the intestine,thereby joining the portions of intestine and forming a tubular pathway.Simultaneously, as the staples are driven and formed, the circular knife3308 is driven through the intestinal tissue ends, cutting the endsadjacent to the inner row of staples. The clinician may then withdrawthe end effector 3000 from the intestine and the anastomosis iscomplete.

FIGS. 46-49 illustrate another surgical end effector 3000′ that may beidentical to the surgical end effector 3000 described above except forthe differences noted below. Those components of the surgical endeffector 3000′ that are the same as the components in the surgical endeffector 3000 described above will be designated with the same elementnumbers. Those components of surgical end effector 3000′ that may besimilar in operation, but not identical to corresponding components ofthe surgical end effector 3000, will be designated with the samecomponent numbers along with a “′”. As can be seen in FIGS. 46-49 , thesurgical end effector 3000′ includes a drive disengagement assembly,generally designated as 3090, that is advantageously configured toenable the clinician to disengage a distal portion of a drive train froma proximal portion of a drive train.

In the depicted embodiment, the drive disengagement assembly 3090 isused in connection with the closure system 3070′ so that in the eventthat the distal portion of the closure system becomes inadvertentlyjammed or otherwise disabled, the clinician may quickly mechanicallyseparate the distal drive train portion from the proximal drive trainportion of the closure system. More specifically and with reference toFIG. 47 , the tension band assembly 3040 and the trocar tip 3042 (SeeFIGS. 42, 43 and 45 ) may also be referred to as the “distal drive trainportion” 3092 of the closure system 3070′ and the closure shaft 3080 andclosure nut assembly 3084 may, for example, be referred to as the“proximal drive train portion” 3094 of the closure system 3070′. As canbe seen in FIG. 47 , one form of the drive disengagement assembly 3090includes a distal coupler member 3095 that is attached to a proximal endof the tension band assembly 3040. The distal coupler member 3095 may beattached to the tension band assembly 3040 by press fit, adhesive,solder, welding, etc. or any combination of such attachmentarrangements. The distal coupler member 3095 is sized to be slidablereceived within a slot 3097 in the proximal coupler member 3085′ that isattached to the closure nut assembly 3084. The distal coupler member3095 includes a distal hole 3096 therethrough that is configured toaxially register with a proximal hole 3098 in the proximal couplermember 3085′ when the distal coupler member 3095 is seated within theslot 3097. See FIG. 48 . The drive disengagement assembly 3090 furthercomprises a drive coupler pin 3099 that is sized to be received withinthe axially aligned holes 3096, 3098 to retainingly couple the distalcoupler member 3095 to the proximal coupler member 3085′. Stated anotherway, the drive coupler pin 3099 serves to mechanically and releasablycouple the distal drive train portion 3092 to the proximal drive trainportion 3094. The drive coupler pin 3099 extends along a coupling axisCA-CA that is transverse to the closure shaft axis CSA. To provideclearance for the drive coupler pin 3099 to move axially relative to thefiring nut 3110, an axial slot 3111 is provided in the firing nut 3110.As can be seen in FIG. 46 , the end effector housing portion 3014′ isprovided with an axially extending clearance slot 3016 to facilitateaxial travel of the drive coupler pin 3099 during the actuation of theclosure system 3070′. Such arrangement enables the clinician to quicklydecouple the distal drive train portion 3092 from the proximal drivetrain portion 3094 at any time during use of the end effector 3000′simply by removing or pulling the drive coupler pin 3099 transverselyout of the holes 3096, 3098 to permit the distal coupler member 3095 tobe disengaged from the proximal coupler member 3085′.

While the drive disengagement assembly 3090 has been described inconnection with the closure system 3070′ of the end effector 3000′, thedrive disengagement assembly could, in the alternative, be employed inconnection with the firing system 3100 of the end effector 3000′. Inother arrangements, a drive disengagement assembly 3090 could beassociated with the closure system and a second drive disengagementassembly may be associated with the firing system. Thus, one or both ofthe proximal drive train portions may be selectively mechanicallyseparated from their respective distal drive train portions. Further,such drive disengagement assembly may be effectively employed inconnection with the closure and/or firing systems of at least some ofother surgical end effectors disclosed herein including but notnecessarily limited to, for example, end effector 1000 and end effector2000 and their respective equivalent arrangements.

FIGS. 50-53 illustrate another surgical end effector 2000′ that may beidentical to the surgical end effector 2000 described above except forthe differences noted below. Those components of the surgical endeffector 2000′ that are the same as the components in the surgical endeffector 2000 described above will be designated with the same elementnumbers. Those components of surgical end effector 2000′ that may besimilar in operation, but not identical to corresponding components ofthe surgical end effector 2000, will be designated with the samecomponent numbers along with a “′”. As can be seen in FIGS. 51-53 , thesurgical end effector 2000′ may be provided with indicator arrangementsfor providing a visual indication as to the firing status of the closureand firing systems.

More particularly and with reference to FIGS. 51 and 52 , the closuresystem 2070 includes a closure system status assembly, generallydesignated as 2090. In one form, for example, the closure system statusassembly 2090 includes a closure indicator member 2092 that is attachedto or otherwise extends from the closure nut 2084′. The closure systemstatus assembly 2090 further includes a closure indicator window 2094 oropening in the end effector housing 2010 such that the position of theclosure indicator member 2092 may be assessed by the clinician byviewing the closure indicator member 2092 through the closure indicatorwindow 2094. Similarly, the firing system 2100′ may include a firingsystem status assembly, generally designated as 2130. In one form, forexample, the firing system status assembly 2130 includes a firingindicator member 2132 that is attached to or otherwise extends from thefiring nut 2110′. The firing system status assembly 2130 furtherincludes a firing indicator window or opening 2134 in the end effectorhousing 2010 such that the position of the firing indicator member 2132may be assessed by the clinician by viewing the firing indicator member2132 through the firing indicator window 2134.

The closure system status assembly 2090 and the firing system statusassembly 2130 reveal the mechanical state of the closure system 2070 andthe firing system 2100. The mechanical state of the distal end of theend effector can generally be observed by the clinician, but itsometimes is covered or obstructed by tissue. The mechanical state ofthe proximal portion of the end effector cannot be seen without a windowarrangement or protruding indicator. Color coding on the exterior of theshaft arrangement and or on the indicator may also be employed toprovide the clinician confirmation that the end effector has been fullyclosed or fired (e.g., indicator on green for fully closed). Forexample, the closure indicator member 2092 may have a closure mark 2093thereon that is viewable through the closure indicator window 2094. Inaddition, the housing 2010 may have a first closure indicia 2095 and asecond closure indicia 2096 adjacent to the closure indicator window2094 to assess the position of the closure indicator 2092. For example,the first closure indicia 2095 may comprise a first bar that has a firstcolor (e.g., range, red, etc.) and the second closure indicia maycomprise a bar or section of a second color that differs from the firstcolor (e.g., green). When the closure mark 2093 on the closure indicatormember 2092 is aligned on the proximal-most end of the first closureindicia bar 2095 (this position is represented by element number 2097 inFIG. 50 ), the clinician can observe that the closure system 2070 is inits unactuated position. When the closure mark 2093 is aligned withinthe first closure indicia bar 2095, the clinician can observe that theclosure system 2070 is partially actuated—but not fully actuated orfully closed. When the closure mark 2093 is aligned with the secondclosure indicia 2096 (represented by element number 2098 in FIG. 50 ),the clinician can observe that the closure system 2070 is in its fullyactuated or fully closed position.

Similarly, the firing indicator member 2132 may have a firing mark 2133thereon that is viewable through the firing indicator window 2134. Inaddition, the housing segment 2014′ may have a first firing indicia 2135and a second firing indicia 2136 adjacent to the firing indicator window2134 to assess the position of the firing indicator 2132. For example,the first firing indicia 2135 may comprise a first firing bar that has afirst firing color (e.g., orange, red, etc.) and the second firingindicia may comprise a second firing bar or section of a second firingcolor that differs from the first firing color (e.g., green). When thefiring mark 2133 on the firing indicator member 2132 is aligned on theproximal-most end of the first firing indicia bar 2135 (this position isrepresented by element number 2137 in FIG. 50 ), the clinician canobserve that the firing system 2100 is in its unactuated position. Whenthe firing mark 2133 is aligned within the first firing indicia bar2135, the clinician can observe that the firing system 2100 is partiallyactuated—but not fully actuated or fully fired. When the firing mark2133 is aligned with the second firing indicia 2136 (represented byelement number 2138 in FIG. 50 ), the clinician can observe that thefiring system 2170 is in its fully actuated or fully fired position.Thus, the clinician may determine the extent to which the closure andfiring systems have been actuated by observing the position of theindicators within their respective windows.

In alternative arrangement, the indicator windows 2094 and 2134 may beprovided in the end effector housing 2010′ such that when the closuresystem 2070 and firing system 2100′ are in their starting or unactuatedpositions, their respective indicators 2092, 2132 may be in full view inthe indicator windows 2094, 2134, respectively. As the closure system2070 and firing system 2100′ are actuated, their indicators 2092, 2132will move out of their indicator windows 2094, 2134. The clinician maythen assess how far each of the systems 2070, 2100′ have been actuatedby observing how much of the indicators 2092, 2132 are viewable throughthe windows 2094, 2134.

The closure system status assembly 2090 and the firing system statusassembly 2130 reveal the mechanical state of the closure system 2070 andthe firing system 2100 whether the end effector 2000′ is attached to thesurgical instrument handle or housing or not. When the end effector 2000is attached to the handle or housing, the closure system status assembly2090 and the firing system status assembly 2130 will afford theclinician with the opportunity to determine the mechanical states ofthose systems as a primary or secondary check to the state shown on thesurgical instrument handle or housing. The closure system statusassembly 2090 and the firing system status assembly 2130 also serve as aprimary check when the end effector 2000′ is detached from the surgicalinstrument handle or housing. Further, such closure system and firingsystem status assemblies may be effectively employed in connection withthe closure and/or firing systems of at least some of other surgical endeffectors disclosed herein including but not necessarily limited to, forexample, end effector 1000 and end effector 3000 and their respectiveequivalent arrangements.

FIGS. 54-60 illustrate another surgical end effector 2000″ that may beidentical to the surgical end effector 2000′ described above except forthe differences noted below. Those components of the surgical endeffector 2000″ that are the same as the components in the surgical endeffector 2000′ and/or end effector 2000 described above will bedesignated with the same element numbers. Those components of surgicalend effector 2000″ that may be similar in operation, but not identicalto corresponding components of the surgical end effector 2000′ and/or2000, will be designated with the same component numbers along with a“″”. As can be seen in FIGS. 54-60 , the surgical end effector 2000″includes a drive disengagement assembly, generally designated as 2200,that is advantageously configured to enable the clinician to disengage adistal portion of a drive train from a proximal portion of a drivetrain.

In the depicted embodiment, the drive disengagement assembly 2200 isused in connection with the closure system 2070″ of the end effector2000″ so that in the event that the distal portion of the closure systembecomes inadvertently jammed or otherwise disabled, the clinician mayquickly mechanically separate the distal drive train portion from theproximal drive train portion of the closure system. More specificallyand with reference to FIG. 56 , the closure beam assembly 2072 may alsobe referred to as the “distal drive train portion” 2202 of the closuresystem 2070″ and the closure shaft 2080 and closure nut assembly 2084″may, for example, be referred to as the “proximal drive train portion”2204 of the closure system 2070″. As can be seen in FIG. 59 , theclosure nut assembly 2084″, while substantially identical to closure nutassemblies 2084, 2084′ described above, is provided in two parts. Morespecifically, closure nut assembly 2084″ includes an upper threadedportion 2210 that is in threaded engagement with the closure shaft 2080and a lower portion 2214 that supports the firing nut 2110 for axialmovement therein in the manner discussed above. The lower portion 2214of the closure nut assembly 2084″ is directly attached to the closurebeam assembly 2072 and includes the closure indicator member 2092″ thatfunctions in the same manner as closure indicator 2092 discussed above.

In at least one form, the drive disengagement assembly 2200 includes adrive coupler pin 2220 that serves to couple the lower portion 2214 ofthe closure nut assembly 2084″ to the upper portion 2210. As can be seenin FIG. 59 , for example, the upper portion 2210 of the closure nutassembly 2084″ includes a first dovetail slot segment 2212 that isconfigured for alignment with a second dovetail slot segment 2216 in thelower portion 2214 of the closure nut assembly 2084″. When the first andsecond dovetail slot segments 2212, 2216 are aligned as shown in FIG. 59, they form hole 2215 into which the barrel portion 2222 of the drivecoupler pin 2220 may be inserted to couple the upper and lower portions2010 and 2014 together as shown in FIG. 56 . Stated another way, thedrive coupler pin 2220 serves to mechanically and releasably couple thedistal drive train portion 2202 to the proximal drive train portion 2204of the closure system 2070″. The drive coupler pin 2220 extends along acoupling axis CA-CA that is transverse to the closure shaft axis CSA.See FIG. 56 . To provide clearance for the drive coupler pin 2220 tomove axially with the closure nut assembly 2084″, the housing segment2014″ of the end effector housing 2010″ is provided with an axiallyextending clearance slot 2224. Such arrangement enables the clinician toquickly decouple the distal drive train portion 2202 from the proximaldrive train portion 2204 at any time during use of the end effector2000″ simply by removing or pulling the drive coupler pin 2220transversely out of the hole 2215 formed by the dovetail slot segments2212, 2216. Once the drive coupler pin 2220 has been removed from thehole 2215, the lower portion 2214 of the closure assembly 2084″ can bemoved relative to the upper portion 2212 to thereby enable the tissue tobe released from between the cartridge module 2060 and the anvilassembly 2140.

FIGS. 54-56 depict the end effector 2000″ in an “open” position prior touse. As can be seen in those Figures, for example, a cartridge module2060 is installed and ready for use. FIGS. 57 and 58 depict the endeffector 2000 in its closed state. That is, the closure beam 2080 hasbeen rotated to drive the closure nut assembly 2084″ in the distaldirection “DD”. Because the lower portion 2214 of the closure nutassembly 2084″ is attached to the upper portion 2210 by the drivecoupler pin 2220, the closure beam assembly 2072 (because it is attachedto the lower portion 2214) is also moved distally to its closed positionto clamp target tissue between the cartridge module 2260 and the anvilassembly 2140. As was also discussed above, the saddle shaped slidebutton 2162 on the housing 2010″ is moved distally to cause theretaining pin to extend through the cartridge housing and into the anvilassembly 2140 to thereby capture the tissue between the cartridge module2060 and the anvil assembly 2140. As was discussed in detail above, whenthe closure nut assembly 2084″ moves distally, the firing nut 2110 alsomoves distally which draws the proximal portion 2106 of the firing shaft2102 out of the elongated passage within the female socket coupler 57′.See FIG. 58 . FIG. 59 illustrates the drive coupler pin 2220 removedfrom the hole 2215 formed by the dovetail slot segments 2212, 2216. Oncethe drive coupler pin 2220 has been removed from the hole 2215, theproximal drive train portion 2202 (closure beam assembly 2072) may bemoved in the proximal direction “PD” by moving the saddle shaped slidebutton 2162 proximally. Such movement of the button 2162 will move theclosure beam assembly 2072, the lower portion 2014 of the closure nutassembly 2084″, the firing nut 2110 and firing bar assembly 2112, aswell as the retaining pin proximally. Such movement will enable thetissue to be released from between the cartridge module 2060 and theanvil assembly 2140.

FIG. 61 is a block diagram of a modular motor driven surgical instrument7000 comprising a handle portion 7002 and a shaft portion 7004. Themodular motor driven surgical instrument 7000 is representative of themodular surgical instrument system generally designated as 2 that, inone form, includes a motor driven surgical instrument 10 that may beused in connection with a variety of surgical end effectors such as, forexample, end effectors 1000, 2000 and 3000 as shown in FIG. 1 . Havingdescribed various functional and operational aspects of the modularmotor driven surgical instrument 10 in detail hereinabove, forconciseness and clarity of disclosure such details will not be repeatedin the following description associated with FIGS. 61-64 . Rather, thedescription of FIGS. 61-64 that follows will focus primarily on thefunctional and operational aspects of the electrical systems andsubsystems of the modular motor driven surgical instrument 7000, whichcan be applied in whole or in part to the modular motor driven surgicalinstrument described hereinabove.

Accordingly, turning now to FIG. 61 the modular motor driven surgicalinstrument 7000 comprises a handle portion 7002 and a shaft portion7004. The handle and shaft portions 7002, 7004 comprise respectiveelectrical subsystems 7006, 7008 electrically coupled by acommunications and power interface 7010. The components of theelectrical subsystem 7006 of the handle portion 7002 are supported bythe previously described control board 100. The communications and powerinterface 7010 is configured such that electrical signals and power canbe readily exchanged between the handle portion 7002 and the shaftportion 7004.

In the illustrated example, the electrical subsystem 7006 of the handleportion 7002 is electrically coupled to various electrical elements 7012and a display 7014. In one instance, the display 7014 is an organiclight emitting diode (OLED) display, although the display 7014 shouldnot be limited in this context. The electrical subsystem 7008 of theshaft portion 7004 is electrically coupled to various electricalelements 7016, which will be described in detail hereinbelow.

In one aspect, the electrical subsystem 7006 of the handle portion 7002comprises a solenoid driver 7018, an accelerometer 7020, a motorcontroller/driver 7022, a handle processor 7024, a voltage regulator7026, and is configured to receive inputs from a plurality of switches7028. Although, in the illustrated embodiment, the switches 7028 aredesignated as Hall switches, the switches 7028 are not limited in thiscontext. In various aspects, the Hall effect sensors or switches 7028may be located either in the end effector portion of the instrument, theshaft, and/or the handle.

In one aspect, the electrical subsystem 7006 of the handle portion 7002is configured to receive signals from a solenoid 7032, a clamp positionswitch 7034, a fire position switch 7036, a motor 7038, a battery 7040,an OLED interface board 7042, and open switch 7044, close switch 7046,and fire switch 7048. In one aspect, the motor 7038 is a brushless DCmotor, although in various aspects the motor is not limited in thiscontext. Nevertheless, the description of the motor 7038 may beapplicable to the motors 80, 480, 580, 680, 750, and 780 previouslydescribed. The solenoid 7032 is representative example of the previouslydescribed shifter solenoid 71.

In one aspect, the electrical subsystem 7008 of the shaft portion 7004comprises a shaft processor 7030. The electrical subsystem 7008 of theshaft is configured to receive signals from various switches and sensorslocated in the end effector portion of the instrument that areindicative of the status of the clamp jaws and cutting element in theend effector. As illustrated in FIG. 61 , the electrical subsystem 7008of the shaft is configured to receive signals from a clamp opened statusswitch 7050, a clamp closed status switch 7052, a fire begin statusswitch 7054, and a fire end status switch 7056, which are indicative ofthe states of the clamp and cutting element.

In one aspect, the handle processor 7024 may be a general purposemicrocontroller suitable for medical and surgical instrumentapplications and including motion control. In one instance, the handleprocessor 7024 may be a TM4C123BH6ZRB microcontroller provided by TexasInstruments. The handle processor 7024 may comprise a 32-bit ARM®Cortex™-M4 80-MHz processor core with System Timer (SysTick), integratednested vectored interrupt controller (NVIC), wake-up interruptcontroller (WIC) with clock gating, memory protection unit (MPU),IEEE754-compliant single-precision floating-point unit (FPU), embeddedtrace macro and trace port, system control block (SCB) and thumb-2instruction set, among other features. The handle processor 7024 maycomprise on-chip memory, such as 256 KB single-cycle Flash up to 40 MHz.A prefetch buffer can be provided to improve performance above 40 MHz.Additional memory includes a 32 KB single-cycle SRAM, internal ROMloaded with TivaWare™ for C Series software, 2 KB EEPROM, among otherfeatures, such as two Controller Area Network (CAN) modules, using CANprotocol version 2.0 part A/B and with bit rates up to 1 Mbps.

In one aspect, the handle processor 7024 also may comprise advancedserial integration including eight universal asynchronousreceiver/transmitters (UARTs) with IrDA, 9-bit, and ISO 7816 support(one UART with modem status and modem flow control). Four SynchronousSerial Interface (SSI) modules are provided to support operation forFreescale SPI, MICROWIRE or Texas Instruments synchronous serialinterfaces. Additionally, six Inter-Integrated Circuit (I2C) modulesprovide Standard (100 Kbps) and Fast (400 Kbps) transmission and supportfor sending and receiving data as either a master or a slave, forexample.

In one aspect, the handle processor 7024 also comprises an ARMPrimeCell® 32-channel configurable μDMA controller, providing a way tooffload data transfer tasks from the Cortex™-M4 processor, allowing formore efficient use of the processor and the available bus bandwidth.Analog support functionality includes two 12-bit Analog-to-DigitalConverters (ADC) with 24 analog input channels and a sample rate of onemillion samples/second, three analog comparators, 16 digitalcomparators, and an on-chip voltage regulator, for example.

In one aspect, the handle processor 7024 also comprises advanced motioncontrol functionality such as eight Pulse Width Modulation (PWM)generator blocks, each with one 16-bit counter, two PWM comparators, aPWM signal generator, a dead-band generator, and aninterrupt/ADC-trigger selector. Eight PWM fault inputs are provided topromote low-latency shutdown. Two quadrature encoder interface (QEI)modules are provided, with a position integrator to track encoderposition and velocity capture using built-in timer.

In one aspect, two ARM FiRM-compliant watchdog timers are provided alongwith six 32-bit general-purpose timers (up to twelve 16-bit). Six wide64-bit general-purpose timers (up to twelve 32-bit) are provided as wellas 12 16/32-bit and 12 32/64-bit capture compare PWM (CCP) pins, forexample. Up to 120 general purpose input/outputs (GPIOs) can be provideddepending on configuration, with programmable control for GPIOinterrupts and pad configuration, and highly flexible pin multiplexing.The handle processor 7024 also comprises lower-power battery-backedhibernation module with real-time clock. Multiple clock sources areprovided for the microcontroller system clock and include a precisionoscillator (PIOSC), main oscillator (MOSC), 32.768-kHz externaloscillator for the hibernation module, and an internal 30-kHzoscillator.

In one aspect, the accelerometer 7020 portion of the electricalsubsystem 7006 of the handle portion 7002 may be amicro-electromechanical system (MEMS) based motion sensor. As is wellknown, MEMS technology combines computers with tiny mechanical devicessuch as sensors, valves, gears, mirrors, and actuators embedded insemiconductor chips. In one example, the MEMS based accelerometer 7020may comprise an ultra low power 8 bit 3-axis digital accelerometer suchas the LIS331DLM provided by STMicroelectronics, for example.

In one aspect, the accelerometer 7020, such as the LIS331DLM, may be anultra low-power high performance three axes linear accelerometerbelonging to the “nano” family, with digital I2C/SPI serial interfacestandard output, with is suitable for communicating with the handleprocessor 7024. The accelerometer 7020 may feature ultra low-poweroperational modes that allow advanced power saving and smart sleep towake-up functions. The accelerometer 7020 may include dynamically userselectable full scales of ±2 g/±4 g/±8 g and it is capable of measuringaccelerations with output data rates from 0.5 Hz to 400 Hz, for example.

In one aspect, the accelerometer 7020 may include self-test capabilityto allow the user to check the functioning of the sensor in the finalapplication. The accelerometer 7020 may be configured to generate aninterrupt signal by inertial wake-up/free-fall events as well as by theposition of the instrument itself. Thresholds and timing of interruptgenerators may be programmable on the fly.

In one aspect, the motor controller/driver 7022 may comprise a threephase brushless DC (BLDC) controller and MOSFET driver, such as theA3930 motor controller/driver provided by Allegro, for example. The3-phase brushless DC motor controller/driver 7022 may be employed withN-channel external power MOSFETs to drive the BLDC motor 7038, forexample. In one instance, the motor controller/driver 7022 mayincorporate circuitry required for an effective three-phase motor drivesystem. In one instance, the motor controller/driver 7022 comprises acharge pump regulator to provide adequate (>10 V) gate drive for batteryvoltages down to 7 V, and enables the motor controller/driver 7022 tooperate with a reduced gate drive at battery voltages down to 5.5 V.Power dissipation in the charge pump can be minimized by switching froma voltage doubling mode at low supply voltage to a dropout mode at thenominal running voltage of 14 V. In one aspect, a bootstrap capacitor isused to provide the above-battery supply voltage required for N-channelMOSFETs. An internal charge pump for the high-side drive allows for dc(100% duty cycle) operation.

An internal fixed-frequency PWM current control circuitry regulates themaximum load current. The peak load current limit may be set by theselection of an input reference voltage and external sensing resistor.The PWM frequency can be set by a user-selected external RC timingnetwork. For added flexibility, the PWM input can be used to providespeed and torque control, allowing the internal current control circuitto set the maximum current limit.

The efficiency of the motor controller/driver 7022 may be enhanced byusing synchronous rectification. The power MOSFETs are protected fromshoot-through by integrated crossover control with dead time. The deadtime can be set by a single external resistor.

In one aspect, the motor controller/driver 7022 indicates a logic faultin response to the all-zero combination on the Hall inputs. Additionalfeatures of the motor controller/driver 7022 include high current3-phase gate drive for N-channel MOSFETs, synchronous rectification,cross-conduction protection, charge pump and top-off charge pump for100% PWM, integrated commutation decoder logic, operation over 5.5 to 50V supply voltage range, diagnostics output, provides +5 V Hall sensorpower, and has a low-current sleep mode.

In one aspect, the modular motor driven surgical instrument 7000 isequipped with a brushless DC electric motor 7038 (BLDC motors, BLmotors) also known as electronically commutated motors (ECMs, ECmotors). One such motor is the BLDC Motor B0610H4314 provided byPortescap. The BLDC Motor B0610H4314 can be autoclavable. The BLDC motor7038 is a synchronous motor that is powered by a DC electric source viaan integrated inverter/switching power supply, which produces an ACelectric signal to drive the motor such as the motor controller/driver7022 described in the immediately foregoing paragraphs. In this context,AC, alternating current, does not imply a sinusoidal waveform, butrather a bi-directional current with no restriction on waveform.Additional sensors and electronics control the inverter output amplitudeand waveform (and therefore percent of DC bus usage/efficiency) andfrequency (i.e., rotor speed).

The rotor part of the BLDC motor 7038 is a permanent magnet synchronousmotor, but in other aspects, BLDC motors can also be switched reluctancemotors, or induction motors. Although some brushless DC motors may bedescribed as stepper motors, the term stepper motor tends to be used formotors that are designed specifically to be operated in a mode wherethey are frequently stopped with the rotor in a defined angularposition.

In one aspect, the BLDC motor controller/driver 7022 must direct therotation of the rotor. Accordingly, the BLDC motor controller/driver7022 requires some means of determining the rotor's orientation/position(relative to the stator coils.) In one instance, the rotor part of theBLDC motor 7038 is configured with Hall effect sensors or a rotaryencoder to directly measure the position of the rotor. Others measurethe back electromotive force (EMF) in the undriven coils to infer therotor position, eliminating the need for separate Hall effect sensors,and therefore are often called sensorless controllers.

In one aspect, the BLDC motor controller/driver 7022 contains 3bi-directional outputs (i.e., frequency controlled three phase output),which are controlled by a logic circuit. Other, simpler controllers mayemploy comparators to determine when the output phase should beadvanced, while more advanced controllers employ a microcontroller tomanage acceleration, control speed and fine-tune efficiency.

Actuators that produce linear motion are called linear motors. Theadvantage of linear motors is that they can produce linear motionwithout the need of a transmission system, such as a ball-and-leadscrew, rack-and-pinion, cam, gears or belts that would be necessary forrotary motors. Transmission systems are known to introduce lessresponsiveness and reduced accuracy. The direct drive, BLDC motor 7038may comprise a slotted stator with magnetic teeth and a moving actuator,which has permanent magnets and coil windings. To obtain linear motion,the BLDC motor controller/driver 7022 excites the coil windings in theactuator causing an interaction of the magnetic fields resulting inlinear motion.

In one aspect, the BLDC motor 7038 is a Portescap BO610 brushless DCmotor that provides a combination of durability, efficiency, torque, andspeed in a package suitable for use in the modular motor driven surgicalinstrument 7000. Such BLDC motors 7038 provide suitable torque density,speed, position control, and long life. The slotless BLDC motor 7038uses a cylindrical ironless coil made in the same winding technique asironless DC motors. The slotted BLDC motors 7038 also are autoclavable.The slotted BLDC motor 7038 may include a stator that consists ofstacked steel laminations with windings placed in the slots that areaxially cut along the inner periphery. The brushless DC slotted BLDCmotor 7038 provides high torque density and heat dissipation, along withhigh acceleration. The three-phase configuration of the BLDC motor 7038includes Wye connections, Hall effect sensors, supply voltage of4.5-24V. The housing of the BLDC motor 7038 may be made of a 303SSmaterial and the shaft may be made of a 17-4 ph material.

In one aspect, the Hall switches 7028 may be Hall effect sensors knownunder the trade name BU520245G and are unipolar integrated circuit typeHall effect sensors. These sensors operate over a supply voltage rangeof 2.4V to 3.6V.

In one aspect, the voltage regulator 7026 replaces the usual PNP passtransistor with a PMOS pass element. Because the PMOS pass elementbehaves as a low-value resistor, the low dropout voltage, typically 415mV at 50 A of load current, is directly proportional to the loadcurrent. The low quiescent current (3.2 μA typically) is stable over theentire range of output load current (0 mA to 50 mA).

In one aspect, the voltage regulator 7026 is a low-dropout (LDO) voltageregulator such as the TPS71533 LDO voltage regulator provided by TexasInstruments. Such LDO voltage regulators 7026 provide the benefits ofhigh input voltage, low-dropout voltage, low-power operation, andminiaturized packaging. The voltage regulator 7026 can operate over aninput range of 2.5 V to 24 V, are stable with any capacitor (≥0.47 μF).The LDO voltage and low quiescent current allow operations at extremelylow power levels and thus the voltage regulator 7026 is suitable forpowering battery management integrated circuits. Specifically, thevoltage regulator 7026 is enabled as soon as the applied voltage reachesthe minimum input voltage and the output is quickly available to powercontinuously operating battery charging integrated circuits of thehandle portion 7002.

In one aspect, the battery 7040 is a lithium-ion polymer (LIPO) battery,polymer lithium ion or more commonly lithium polymer batteries(abbreviated Li-poly, Li-Pol, LiPo, LIP, PLI or LiP) are rechargeable(secondary cell) batteries. The LIPO battery 7040 may comprise severalidentical secondary cells in parallel to increase the discharge currentcapability, and are often available in series “packs” to increase thetotal available voltage.

Additional power for the modular motor driven surgical instrument 7000may be provided by a synchronous step down DC-DC converter 7058 (FIG.63A) optimized for applications with high power density such as theTPS6217X family provided by Texas Instruments. A high switchingfrequency of typically 2.25 MHz may be employed to allow the use ofsmall inductors and provides fast transient response as well as highoutput voltage accuracy by utilization of the DCS-Control™ topology.

With a wide operating input voltage range of 3V to 17V, the synchronousstep down DC-DC converter 7058 (FIG. 63A) is well suited for modularmotor driven surgical instrument 7000 systems powered from either aLi-Ion or other battery as well as from 12V intermediate power rails. Inone aspect, a synchronous step down DC-DC converter 7058 supports up to0.5 A continuous output current at output voltages between 0.9V and 6V(with 100% duty cycle mode).

Power sequencing is also possible by configuring the Enable andopen-drain Power Good pins. In Power Save Mode, the synchronous stepdown DC-DC converter 7058 (FIG. 63A) show quiescent current of about 17μA from VIN. Power Save Mode is entered automatically and seamlessly ifload is small and maintains high efficiency over the entire load range.In Shutdown Mode, the synchronous step down DC-DC converter 7058 isturned off and shutdown current consumption is less than 2 μA.

In one aspect, the OLED interface 7042 is an interface to the OLEDdisplay 7014. The OLED display 7014 comprises organic light-emittingdiodes in which the emissive electroluminescent layer is a film oforganic compound which emits light in response to an electric current.This layer of organic semiconductor is situated between two electrodes,where in general at least one of these electrodes is transparent. TheOLED display 7014 may include OLEDs from two main families. Those basedon small molecules and those employing polymers. Adding mobile ions toan OLED creates a light-emitting electrochemical cell or LEC, which hasa slightly different mode of operation. The OLED display 7014 can useeither passive-matrix (PMOLED) or active-matrix addressing schemes.Active-matrix OLEDs (AMOLED) require a thin-film transistor backplane toswitch each individual pixel on or off, but allow for higher resolutionand larger display sizes. In one instance, the OLED display 7014 workswithout a backlight. Thus, it can display deep black levels and can bethinner and lighter than a liquid crystal display (LCD), making itideally suitable for use on the handle portion 7002 of the modular motordriven surgical instrument 7000.

In one aspect, the shaft processor 7030 of the electrical subsystem 7008of the shaft portion 7004 may be implemented as an ultra-low power16-bit mixed signal MCU, such as the MSP430FR5738 Ultra-low Power MCUprovided by Texas Instruments. The shaft processor 7030 is an ultra-lowpower microcontroller consisting of multiple devices featuring embeddedFRAM nonvolatile memory, ultra-low power 16-bit MSP430 CPU, andadditional peripherals targeted for various applications. Thearchitecture, FRAM, and peripherals, combined with seven low-powermodes, are optimized to achieve extended battery life in portable andwireless sensing applications. FRAM is a new nonvolatile memory thatcombines the speed, flexibility, and endurance of SRAM with thestability and reliability of flash, all at lower total powerconsumption. Peripherals include 10-bit A/D converter, 16-channelcomparator with voltage reference generation and hysteresiscapabilities, three enhanced serial channels capable of I2C, SPI, orUART protocols, internal DMA, hardware multiplier, real-time clock, five16-bit timers, among other features.

The shaft processor 7030 includes a 16-bit RISC architecture up to 24MHz clock and operates over a wide supply voltage range of 2 V to 3.6 Vand is optimized for ultra-low power modes. The shaft processor 7030also includes intelligent digital peripherals, an ultra-low powerferroelectric RAM, and up to 16 KB of nonvolatile memory. The embeddedmicrocontroller provides ultra-low power writes, a fast write cycle of125 ns per word, 16 KB in 1 ms, and includes built in Error Coding andCorrection (ECC) and Memory Protection Unit (MPU).

Having described the electrical system, subsystems, and components ofthe handle and shaft portions 7002, 7004 of the modular motor drivensurgical instrument 7000, the functional aspects of the control systemwill now be described. Accordingly, in operation, the electricalsubsystem 7006 of the handle portion 7002 is configured to receivesignals from the open switch 7044, close switch 7046, and fire switch7048 supported on a housing of the handle portion 7002. When a signal isreceived from the close switch 7046 the handle processor 7024 operatesthe motor 7038 to initiate closing the clamp arm. Once the clamp isclosed, the clamp closed status switch 7052 in the end effector sends asignal to the shaft processor 7030, which communicates the status of theclamp arm to the handle processor 7024 through the communications andpower interface 7010.

Once the target tissue has been clamped, the fire switch 7048 may beactuated to generate a signal, which is received by the handle processor7024. In response, the handle processor 7024 actuates the transmissioncarriage to its second drive position such that actuation of the motor7038 will result in the rotation of a second drive shaft, as describedin detail above in connection with FIGS. 1-8 . Once the cutting memberis positioned, the fire begin status switch 7054 located in the endeffector sends a signal indicative of the position of the cutting memberto the shaft processor 7030, which communicates the position back to thehandle processor 7024 through the communications and power interface7010.

Actuating the first switch 7048 once again sends a signal to the handleprocessor 7038, which in response actuates the second drive system andthe firing system in the end effector to drive the tissue cutting memberand wedge sled assembly distally through the surgical staple cartridge.Once the tissue cutting member and wedge sled assembly have been drivento their distal-most positions in the surgical staple cartridge, thefire end switch 7056 sends a signal to the shaft processor 7030 whichcommunicates the position back to the handle processor 7024 through theinterface 7010. Now the fire switch 7048 may be activated to send asignal to the handle processor 7024, which operated the motor 7038 inreverse rotation to return the firing system to its starting position.

Actuating the open switch 7044 once again sends a signal to the handleprocessor 7024, which operates the motor 7038 to open the clamp. Onceopen, the clamp opened status switch 7050 located in the end effectorsends a signal to the shaft processor 7030, which communicates theposition of the clamp to the handle processor 7024. The clamp positionswitch 7034 and the fire position switch 7036 provide signals to thehandle processor 7024 that indicate the respective positions of theclamp arm and the cutting member.

FIG. 62 is a table 7060 depicting the total time it takes to complete astroke and the load current requirements for various operations ofvarious device shafts. The first column 7062 from the left listscircular, contour, and TLC devices/shafts. These devices/shafts arecompared over three different operations closing, opening, and firing asshown in the second column 7064. The third column 7066 depicts the totaltime in seconds required for the device/shaft listed in the first column7063 to complete one stroke. The fourth column 7068 lists the loadcurrent requirements in amperes for the devices/shafts listed in thefirst column 7062 to complete the operation in the second column 7064for a complete stroke as indicated in the third column 7066. Asindicated in the chart, closing and opening the clamp arm takes aboutthe same time for each of the device/shafts listed in the first column7062. For the firing operation, the circular device/shaft requires themost load current at 15.69 A and the TLC device/shaft requires the leastamount load current at 0.69 A.

FIG. 63A is a detail diagram of the electrical system in the handleportion 7002 of the modular motor driven surgical instrument 7000. Asshown in FIG. 63A, the voltage regulator 7026 and DC-DC converter 7058provide the operating voltages for the electrical system. The voltageregulator 7026 regulates the battery 7040 voltage. The handle processor7024 receives inputs from the accelerometer 7020. The VSS-ON/OFF Logicsupply 7086 provides the input voltage to the handle processor 7024 andthe VSS input to the DC-DC converter 7058.

A tri-color LED 7072 is electrically coupled to the handle processor7024. The handle processor 7024 energizes either the red, blue, or greenLED 7072 to provide visual feedback.

Three Hall effect sensor 7028 U10, U11, U12 provide three separate Halleffect outputs U1_Hall1, U1_Hall2, U1_Hall3 which are coupled to thehandle processor 7024 as shown. The U1_Hall3 output drives an onboardLED 7088. In one aspect, the Hall effect sensor outputs U1_Hall1,U1_Hall2, U1_Hall3, and the ANALOG_CLAMP signal are coupled to thehandle processor 7024 to determine the position of the clamp arm and thecutting member at the end effector portion of the modular motor drivensurgical instrument 7000, or the positions of other elements of theinstrument 7000.

The user switch 7070 is a representative example of the previouslydescribed “rocker-trigger” 110 that is pivotally mounted to a pistolgrip portion of the handle. The user switch 7070 is operable to actuatea first motor switch 7044 that is operably coupled to the handleprocessor 7024. The first motor switch 7044 may comprise a pressureswitch which is actuated by pivoting the user switch 7070 into contacttherewith. Actuation of the first motor switch 7044 will result inactuation of the motor 7038 such that the drive gear rotates in a firstrotary direction. A second motor switch 7046 is also coupled to thehandle processor 7024 and mounted for selective contact by the userswitch 7070. Actuation of the second motor switch 7046 will result inactuation of the motor 7038 such that the drive gear is rotated in asecond direction. A fire switch 7048 is coupled to handle processor7024. Actuation of the fire switch 7048 results in the axial movement ofthe transmission carriage to advance the cutting element as wasdescribed above.

A Joint Test Action Group (JTAG) 7074 input is also coupled to thehandle processor 7024. The JTAG 7074 input is the IEEE 1149.1 StandardTest Access Port and Boundary-Scan Architecture devised for integratedcircuit (IC) debug ports. The handle processor 7024 implements the JTAG7074 to perform debugging operations like single stepping andbreakpointing.

A UART 7076 is coupled to the handle processor 7024. The UART 7076translates data between parallel and serial forms. The UART 7076 iscommonly used in conjunction with communication standards such as EIA,RS-232, RS-422 or RS-485. The universal designation indicates that thedata format and transmission speeds are configurable. The electricsignaling levels and methods (such as differential signaling etc.) arehandled by a driver circuit external to the UART 7076. The UART 7076 maybe an individual (or part of an) integrated circuit used for serialcommunications over the serial port of the handle processor 1024. TheUART 7076 can be included in the handle processor 1024.

A description of the remaining functional and operational aspects of theelectrical subsystem 7006 of the handle portion 7002 of the modularmotor driven surgical instrument 7000 will now be provided in connectionwith FIG. 63B. As shown, the handle processor 7024 provides a signal todrive the solenoid 7032. A shaft module 7078 provides position signalsSHAFT_IDO, SHAFT_ID1, CLAMP_HOME, and FIRE_HOME to the handle processor7024. A gear position module 7080 provides the position of the clamp andthe cutting element to the handle processor 7024. The positionalinformation provided by the shaft module 7078 and the gear positionmodule 7080 enable the handle processor 7024 to properly activate themotor 7038 when the user switch 7070 signals are received to open theclamp, close the clamp, and/or fire the cutting element.

The motor controller 7022 receives commands from the handle processor7024 and provides commands to the MOSFET driver 7084, which drives the3-phase BLDC motor 7038 (FIG. 61 ). As previously described, the BLDCmotor controller 7022 must direct the rotation of the rotor.Accordingly, the BLDC motor controller/driver 7022 determines theposition/orientation of the rotor relative to the stator coils.Accordingly, the rotor part of the BLDC motor 7038 is configured withHall effect sensors 7028 to directly measure the position of the rotor.The BLDC motor controller 7022 contains 3 bi-directional outputs (i.e.,frequency controlled three phase output), which are controlled by alogic circuit.

Accordingly, as described in FIGS. 61, 63A, 63B, and 64 a motor controlsystem comprising the motor controller 7022, the motor driver 7084, themotor Hall effect sensors 7028 in combination with the gear positionmodule 7080 and/or the shaft module 7078 is operable to synchronize thegears such that the male couplers in the handle portion smoothly couplewith the female couplers in the shaft portion of the surgicalinstruments described herein. In one instance, for example, althoughsome tolerances may be provided for ease of shifting or keying, themotor control system is configured to track the position of the gears toensure that the gears do not stop in a position that would prohibitshifting from one to the other or installing the two rotary keyings. Inanother instance, the motor may be configured to be slowly indexedduring installation or shifting to resolve any minor out ofsynchronization conditions. These same issues may be encountered withthe example described in connection with FIG. 6 when the instrumentshifts between two drives and not just when installing newend-effectors. This situation may be resolved by proper synchronizationof the gears employing the motor control system described in connectionwith FIGS. 61, 63A, 63B, and 64 . In other instances, encoders may beprovided to track the rotations of the gears/gear shafts.

FIG. 64 is block diagram of the electrical system of the handle andshaft portions of the modular motor driven surgical instrument. As shownin FIG. 64 , the handle processor 7024 receives inputs from the openswitch 7044, close switch 7046, fire switch 7048, clamp position switch7034, and fire position switch 7036. In addition, the handle processor7024 receives inputs from a clamp home switch 7090 and a fire homeswitch 7092 from the shaft module 7078. Using various combinations ofthese switch inputs, the handle processor 7024 provides the propercommands to the motor 7038 and the solenoid 7032. A battery monitoringcircuit 7088 monitors the power input to the handle processor 7024relative to ground. The handle processor 7024 drives the tri-color LED7072. The accelerometer 7020 provides three-axis orientation inputs tothe handle processor 7024 to determine various parameters such asorientation of the instrument 7000 and whether the instrument 7000 hasbeen dropped. The voltage regulator 7026 provides the regulated powersupply for the system. A current sensing module 7094 is provided tosense the current drawn from the power supply.

FIG. 65 illustrates a mechanical switching motion control system 7095 toeliminate microprocessor control of motor functions. In the systemdescribed in connection with FIGS. 61-64 , a microprocessor such as thehandle processor 7024 is employed to control the function of the motor7038. The handle processor 7024 executes a control algorithm based onthe various states of the switches deployed throughout the instrument7000. This requires the use of the handle processor 7024 and associatedidentification functions to provide control for different end effectors.

As shown in FIG. 65 , however, an alternative technique may be employedto control the motor 7038 that eliminates the need for the handleprocessor 7024 by placing motion related switched 7096A, 7096B, 7096C,7096D in the end effector shaft. The switches 7096A-D are thenconfigured to turn on and off specific functions of the motor 7038 or toreverse the direction of the motor 7038 based on where specific endeffector components are positioned. In one instance, a switch thatindicates full deployment of the cutting member could be employed toswitch the functions of the motor 7038 to reverse direction and withdrawthe cutting member. In another instance, the switches 7096A-D could beconfigured to detect pressure or force such that a simple closure of theanvil down on the tissue would provide an on/off signal back to theclosure motor 7038 to stop the closure motion.

In various instances, a surgical instrument can include a handle, anelectric motor positioned within the handle, a shaft attachable to thehandle, and an end effector extending from the shaft, wherein theelectric motor is configured to motivate an end effector function at theend effector. In some instances, the surgical instrument can include acontrol system comprising one or more sensors and a microprocessor whichcan receive input signals from the sensors, monitor the operation of thesurgical instrument, and operate the electric motor to perform the endeffector function in view of the sensor input signals. In at least onesuch instance, the handle of the surgical instrument can be usable withmore than one shaft. For instance, a linear stapling shaft or a circularstapling shaft could be assembled to the handle. The handle can includeat least one sensor configured to detect the type of shaft that has beenassembled thereto and communicate this information to themicroprocessor. The microprocessor may operate the electric motordifferently in response to the sensor input signals depending on thetype of the shaft that has been assembled to the handle. For instance,if the electric motor is configured to operate a closing system of theend effector, the microprocessor will rotate the electric motor in afirst direction to close an anvil of the circular stapler shaft and asecond, or opposite, direction to close an anvil of the linear staplershaft. Other control systems are envisioned in which the sameoperational control of the electric motor can be achieved without theuse of a microprocessor. In at least one such instance, the shaftsand/or the handle of the surgical instrument can include switches whichcan operate the surgical instrument differently depending on the type ofthe shaft that has been assembled to the handle.

In various instances, a surgical instrument system can include a powersource, a first motor configured to perform a first end effectorfunction, a second motor configured to perform a second end effectorfunction, and a control system of switches configured to selectivelyplace the power source in communication with the first motor and thesecond motor in response to the control system of switches. In variousinstances, such a surgical instrument system may not include amicroprocessor. The first motor can comprise a closing motor of aclosing system configured to close an anvil of the end effector and thesecond motor can comprise a firing motor of a firing system configuredto fire staples from a staple cartridge of the end effector. The controlsystem of switches can include a closure trigger switch which, whenclosed, can close a closure power circuit which couples the power sourceto the closing motor. The control system can further include a closureend-of-stroke switch which can be opened by the closure system when theanvil is in a fully closed position and open the closure power circuitto stop the closing motor and the closure drive. The control system ofswitches can also include a firing trigger switch which can be part of afiring power circuit which couples the power source to the firing motor.In various circumstances, the default condition of the firing powercircuit can be open which can prevent the firing motor from beingoperated prior to firing power circuit being closed. Thus, closing thefiring switch alone may not close the firing power circuit and operatethe firing motor. The firing power circuit can further include a secondclosure end-of-stroke switch which can be closed by the closure systemwhen the anvil is in a fully closed position. Closing the firing switchand the second closure end-of-stroke switch may close the firing powercircuit and operate the firing motor. The control system can furtherinclude a firing end-of-stroke switch can be opened by the firing drivewhen the firing drive reaches the end of its firing stroke. The openingof the firing end-of-stroke switch can open the firing power circuit andstop the firing motor. The control system can further include a secondfiring end-of-stroke switch which can be closed by the firing drive toclose a reverse firing power circuit which reverses the polarity of thepower applied to the firing motor and operates the firing motor in anopposite direction and retracts the firing drive. Closing the reversefiring power circuit may also require the firing trigger switch to be ina closed condition. When the firing drive reaches its fully-retractedposition, it can close a proximal firing switch. The closure of theproximal firing switch can close a reverse closing power circuit whichcan reverse the polarity of the power applied to the closing motor andoperate the closing motor in an opposite direction and open the anvil.Closing the reverse closure power circuit may also require the closuretrigger switch to be in a closed condition. When the anvil reaches itsfully-open position, the anvil can open a proximal closure switch whichcan open the reverse closing power circuit and stop the closing motor.This is but one example.

In various instances, as described herein, a handle of a surgicalinstrument can be used with several different shaft assemblies which canbe selectively attached to the handle. In some instances, as alsodescribed herein, the handle can be configured to detect the type ofshaft that has been assembled to the handle and operate the handle inaccordance with a control system contained within the handle. Forinstance, a handle can include a microprocessor and at least one memoryunit which can store and execute a plurality of operating programs, eachof which are configured to operate a specific shaft assembly. Otherembodiments are envisioned in which the handle does not include acontrol system; rather, the shaft assemblies can each comprise their owncontrol system. For instance, a first shaft assembly can comprise afirst control system and a second shaft assembly can comprise a secondcontrol system, and so forth. In various instances, the handle maycomprise an electrical motor, a power source, such as a battery and/oran input cable, for example, and an electrical circuit configured tooperate the electrical motor based on control inputs from the attachedshaft assembly. The handle may further comprise an actuator which, inconjunction with the shaft control system, may control the electricalmotor. In various instances, the handle may not comprise additionalcontrol logic and/or a microprocessor, for example, for controlling theelectrical motor. With the exception of the handle actuator, the controlsystem of the shaft assembly attached to the handle would include thecontrol logic needed to operate the electrical motor. In variousinstances, the control system of the shaft assembly may include amicroprocessor while, in other instances, it may not. In some instances,the first control system of a first shaft assembly can include a firstmicroprocessor and the second control system of a second shaft assemblycan include a second microprocessor, and so forth. In various instances,a handle can include a first electrical motor, such as a closing motor,for example, and a second electrical motor, such as a firing motor, forexample, wherein the control system of the attached shaft assembly canoperate the closing motor and the firing motor. In certain instances,the handle can comprise a closing actuator and a firing actuator. Withthe exception of the closing actuator and the firing actuator, thecontrol system of the shaft assembly attached to the handle wouldinclude the control logic needed to operate the closing motor and thefiring motor. In various instances, a handle can include a shaftinterface and each shaft assembly can include a handle interfaceconfigured to engage the shaft interface. The shaft interface caninclude an electrical connector configured to engage an electricalconnector of the handle interface when a shaft assembly is assembled tothe handle. In at least one instance, each connector may comprise onlyone electrical contact which are mated together such that only onecontrol path is present between the handle and the shaft assembly. Inother instances, each connector may comprise only two electricalcontacts which form two mated pairs when the shaft assembly is attachedto the handle. In such instances, only two control paths may be presentbetween the handle and the shaft assembly. Other embodiments areenvisioned in which more than two control paths are present between thehandle and the shaft assembly.

In various instances, surgical end effector attachments can becompatible with a surgical instrument handle. For example, a surgicalend effector can be coupled to the handle of a surgical instrument andcan deliver and/or implement a drive motion that was initiated in thehandle of the surgical instrument. Referring to FIGS. 73 and 74 , thesurgical end effector 8010 can be one of the several surgical endeffectors that can be compatible with the handle 8000 of a surgicalinstrument. Various different surgical end effectors are describedthroughout the present disclosure and are depicted throughout theassociated figures. The reader will appreciate that these various,different surgical end effectors described and depicted herein may becompatible with the same surgical instrument handle and/or can becompatible with more than one type of surgical instrument handle, forexample.

The handle 8000 can include drive systems, for example, which can beconfigured to transfer a drive motion from the handle 8000 of thesurgical instrument to a component, assembly and/or system of the endeffector 8010. For example, the handle 8000 can include a first drivesystem 8002 a and a second drive system 8004 a. In certain instances,one of the drive systems 8002 a, 8004 a can be configured to deliver aclosing drive motion to the jaw assembly of the end effector 8010 (FIG.73 ), for example, and one of the drive systems 8002 a, 8004 a can beconfigured to deliver a firing drive motion to a firing element in theend effector 8010, for example. The drive systems 8002 a, 8004 a can beconfigured to transfer a linear motion, displacement, and/or translationfrom the handle 8000 to the end effector 8010. In various instances, thefirst drive system 8002 a can include a drive bar 8006, which can beconfigured to translate and/or be linearly displaced upon activation ofthe first drive system 8002 a. Similarly, the second drive system 8004 acan include a drive bar 8008, which can be configured to translateand/or be linearly displaced upon activation of the second drive system8004 a.

In various instances, the end effector assembly 8010 can include a firstdrive system 8002 b, which can correspond to the first drive system 8002a of the handle 8000, for example, and can also include a second drivesystem 8004 b, which can correspond to the second drive system 8004 a ofthe handle 8000, for example. In various instances, the first drivesystem 8002 b in the end effector 8010 can include a drive element 8012,which can be operably and releasably coupled to the drive bar 8006 ofthe first drive system 8002 a of the handle 8000, for example, and canbe configured to receive a linear motion from the drive bar 8006, forexample. Additionally, the second drive system 8004 b of the endeffector 8010 can include a drive element 8014, which can be operablyand releasably coupled to the drive bar 8008 of the second drive system8004 a of the handle 8000, for example, and can be configured to receivea linear motion from the drive bar 8008, for example.

In various instances, the handle 8000 and/or the end effector 8010 caninclude a coupling arrangement, which can be configured to releasablycouple the drive bar 8006 to the drive element 8012, for example, and/orthe drive bar 8008 to the drive element 8014, for example. In otherwords, the coupling arrangement can couple the first drive system 8002 aof the handle 8000 to the first drive system 8002 b of the end effector8010 and the second drive system 8004 a of the handle 8000 to the seconddrive system 8004 b of the end effector 8010 such that a drive forceinitiated in the handle 8000 of the surgical instrument can betransferred to the appropriate drive system 8002 b, 8004 b of theattached surgical end effector 8010. Though the surgical system depictedin FIGS. 73 and 74 includes a pair of drive systems 8002 a, 8004 a inthe handle 8000 and a corresponding pair of drive system 8002 b, 8004 bin the end effector 8010, the reader will appreciate that the variouscoupling arrangements disclosed herein can also be used in a surgicalend effector and/or handle comprising a single drive system or more thantwo drive systems, for example.

In various instances, a coupling arrangement for coupling a drive systemin the handle of a surgical instrument to a drive system in an attachedend effector can include a latch, which can be configured to retain andsecure the connection between the corresponding handle and end effectordrive systems. As described in greater detail herein, the latch can bespring-loaded, and can be coupled to a trigger, for example, which canbe configured to operably overcome the bias of a spring to unlock, open,and/or release the coupling arrangement, for example. In variousinstances, the coupling arrangement can include independent and/ordiscrete coupling mechanisms and/or joints for each drive system 8002 b,8004 b in the surgical end effector 8010. In such instances, one of thedrive systems 8002 b, 8004 b can be activated without activating theother drive system 8002 b, 8004 b. In other instances, the drive systems8002 b, 8004 b can be activated simultaneously and/or concurrently, forexample.

Referring now to FIGS. 66-72 , a coupling arrangement 8100 for use witha surgical end effector is depicted. For example, a surgical endeffector can be attached to a handle 8170 (FIGS. 67-69 ) of a surgicalinstrument via the coupling arrangement 8100, for example. In variousinstances, the coupling arrangement 8100 can include a coupler housingor frame 8102, for example. The coupler housing 8102 can be positionedwithin a proximal attachment portion of the end effector, for example.Additionally, the coupler housing 8102 can include a carriage 8104, forexample, which can be configured to move relative to the coupler housing8102, for example. For example, the coupler housing 8102 can include achannel 8103, which can be dimensioned and structured to receive theslidable and/or shiftable carriage 8104. For example, the carriage 8104can be restrained by the coupler housing 8102, such that the carriage8104 is movably held in the channel 8103 and is configured to moveand/or slide within the channel 8103. The channel 8103 can guide and/orrestrain movement of the carriage 8014 relative to the housing 8102, forexample. In certain instances, the carriage 8104 can have a rampedsurface, such as a ramp or wedge 8106, for example, which can furtherguide and/or facilitate movement of the carriage 8104, for example.

In various instances, the coupling arrangement 8100 can include atrigger 8120 in sliding engagement with the ramp 8106 of the carriage8104. For example, the trigger 8120 can include an inclined surface 8122that is configured to slide along the ramp 8106 of the carriage 8104when the trigger 8120 is moved between a first, or unactuated, position(FIG. 68 ) and a second, or actuated, position (FIGS. 67 and 69 ), forexample. In certain instances, the coupling arrangement 8100 can includea guide, such as guide rails 8110, for example, which can be positionedand structured to guide the trigger 8120 between the first, unactuatedposition and the second, actuated position, for example. For example,the coupler housing 8102 can include a pair of guide rails 8110, whichcan define an actuation path for the trigger 8120.

In various instances, when the trigger 8120 is moved along the actuationpath defined by at least one guide rail 8110 in a direction D₁ (FIGS. 67and 69 ) from the unactuated position (FIG. 68 ) to the actuatedposition (FIGS. 67 and 69 ), for example, the carriage 8104 can beshifted downward or in a direction D₃ (FIGS. 67 and 69 ) within thechannel 8103 via the inclined surface 8122 of the trigger 8120 and theramp 8106 of the carriage 8104. Accordingly, activation of the trigger8120 can shift the carriage 8104 relative to the coupler housing 8102,trigger 8120 and/or various other components, assemblies, and/or systemsof the coupling arrangement 8100, for example.

In various instances, when the trigger 8120 is moved along at least oneguide rail 8110 in a direction D₂ (FIG. 68 ) from the actuated position(FIGS. 67 and 69 ) to the unactuated position (FIG. 68 ), for example,the carriage 8104 can be shifted upward or in a direction D₄ (FIG. 68 )within the channel 8103 via the inclined surface 8122 of the trigger8120 and the ramp 8106 of the carriage 8104. Accordingly, actuation ofthe trigger 8120 can affect movement of the carriage 8104 relative tothe coupler housing 8102, for example. In certain instances, a springand/or other biasing mechanism can be configured to bias the carriage8104 and/or the trigger 8120 toward a predefined position relative tothe channel 8103 and/or the coupler housing 8102, for example.

Referring now to FIG. 66 , in various instances, a slot 8112 can bedefined in the coupler housing 8102 and/or the end effector. The slot8112 can be dimensioned to receive a drive member 8172 of the handle8170 of a surgical instrument, for example. In certain instances, a pairof slots 8112 can be defined in the coupler housing 8102, and each slot8112 can be configured to receive one of the drive members 8172 of thehandle 8170, for example. As described in greater detail herein, thedrive members 8172 can be coupled to and/or otherwise driven by a drivesystem in the handle 8170. For example, each drive member 8172 can becoupled to and/or otherwise driven by a linear actuator of a drivesystem in the handle 8170, which can be configured to translate anddeliver a linear drive motion to the corresponding drive system in theend effector, for example.

In various instances, the carriage 8104 can also be configured to moveand/or shift relative to a drive member socket 8130 of the couplingarrangement 8100. The drive member socket 8130 can be configured toreceive one of the drive members 8172 from the handle 8170, for example.Referring primarily to FIG. 71 , the socket 8103 can include an opening8136, which can be dimensioned and/or structured to receive a drivesystem component of the handle 8170. For example, referring primarily toFIG. 67 , the opening 8136 can be configured to receive a distal portionof the drive bar 8172. In such instances, when the drive bar 8172 issecured within the opening 8136 in the socket 8130, as described ingreater detail herein, the socket 8130 can be configured to transfer adrive force from the handle 8170 to the surgical end effector via thedrive bar 8172 and socket 8130 engagement, for example.

Referring still to FIG. 67 , the drive bar 8172 can include a bevel 8176and a groove or divot 8174, for example, which can facilitate engagementand/or locking of the drive bar 8172 to the socket 8130. In variousinstances, the drive member socket 8130 can be secured and/or fixedwithin the end effector and/or within the coupler housing 8102, forexample, and the carriage 8104 can be configured to move and/or shiftrelative to and/or around the socket 8130 when the carriage 8104 slideswithin the channel 8103 in the coupler housing 8102.

Referring primarily to FIG. 71 , the socket 8130 can include at leastone flexible tab 8132 a, 8132 b. The flexible tab 8132 a, 8132 b can beinwardly biased toward the opening 8136 and/or can include aninwardly-biased tooth, for example. In certain instances, the flexibletab 8132 a, 8132 b can include the tooth 8133, for example, which can beconfigured to engage the groove 8174 in the drive bar 8172 when thedrive bar 8172 is inserted into the opening 8136 in the socket 8130. Forexample, the bevel 8176 of the drive bar 8172 can pass by the tooth 8133within the socket opening 8136, and can flex or deflect the tab 8132outward from the opening 8136. As the drive bar 8172 continues to enterthe opening 8136 of the socket 8130, the tooth 8136 of the tab 8132 a,8132 b can engage or catch the groove 8174 in the drive bar 8172. Insuch instances, the tooth 8136-groove 8174 engagement can releasablyhold the drive bar 8172 within the socket 8130, for example.

In various instances, the socket 8130 can include a recess 8134, whichcan be configured to receive a spring 8150, for example. In otherinstances, the socket 8136 can include more than one recess 8134, andthe coupling arrangement 8100 can include more than one spring 8150, forexample. Moreover, in certain instances, the socket 8130 can includemore than one flexible tab 8132 a, 8132 b. For example, the socket 8130can include a pair of laterally-positioned tabs 8132 a, 8132 b. A firsttab 8132 a can be positioned on a first lateral side of the socket 8130,for example, and a second tab 8132 b can be positioned on a secondlateral side of the socket 8130, for example. In certain instances, thetabs 8132 a, 8132 b can be deflected outward from the opening 8136 toaccommodate entry of the drive bar 8172, for example. In otherinstances, the socket 8130 may not include an inwardly-biased tab and/orcan include more than two tabs, for example.

In various instances, the coupling arrangement 8100 can also include alatch or sleeve 8140, which can be movably positioned relative to thesocket 8130. For example, the latch 8140 can include an opening 8142(FIG. 72 ), which can be dimensioned and structured to at leastpartially surround at least a portion of the socket 8130. For example,the latch 8140 can be positioned around the socket 8130, and can bemovably positioned relative to the tabs 8132 a, 8132 b of the socket8130, for example. In various instances, the spring 8150 can bepositioned between a portion of the socket 8130 and a portion of thelatch 8140, for example, such that the spring 8150 can bias the latch8140 toward a socket-latching position (FIG. 68 ). For example, thespring 8150 can bias the latch 8140 into the socket-latching position(FIG. 68 ) in which the latch 8140 is positioned to surround and/orrestrain outward deflection of the tab(s) 8132 a, 8132 b.

In various instances, when the latch 8140 is positioned to limit and/orprevent outward deflection of the tab(s) 8132 a, 8132 b, i.e., in thesocket-latching position, outward movement of the tab(s) 8132 a, 8132 baway from the opening 8136 can be limited, such that the tab(s) 8132 a,8132 b can block and/or otherwise prevent entry and/or release of thedrive bar 8172 relative to the opening 8136 in the socket 8130, forexample. Moreover, when the trigger 8120 moves from the unactuatedposition (FIG. 68 ) to the actuated position (FIGS. 67 and 69 ), thelatch 8140 can overcome the bias of the spring(s) 8150, for example, andcan be moved from the socket-latching position (FIG. 68 ) to anunlatched position (FIGS. 67 and 69 ). When in the unlatched position,the latch 8140 can be shifted away from the flexible tab(s) 8132 a, 8132b, such that the flexible tab(s) 8132 a, 8132 b can be deflectedoutward, for example, and the socket 8130 can receive the drive bar8172, for example.

In various instances, the latch 8140 can comprise a nub or protrusion8144. Furthermore, referring primarily to FIG. 70 , the carriage 8104 inthe coupler housing 8102 can include a biasing member 8108. The biasingmember 8108 can include a ramp or angled surface, for example, which canbe configured to bias the nub 8144, and thus the latch 8140, between thefirst or socket-latching position (FIGS. 67 and 69 ) and the second, orlatched, position (FIG. 68 ), for example. For example, when movement ofthe trigger 8120 causes the carriage 8104 to shift relative to thecoupler housing 8102 and the socket 8130, as described herein, the nub8144 can slide along the angled surface of the biasing member 8108, suchthat the latch 8140 moves relative to the flexible tab 8132 of thesocket 8130. In such instances, the activation of the trigger 8120 canovercome the bias of the spring 8150 and retract the latch 8140 from thesocket-latching position around the flexible tab(s) 8132 of the socket8130 to the unlatched position. In such instances, when the latch 8140is retracted, the flexible tab(s) 8132 can be permitted to deflectand/or engage a driving bar 8172. Moreover, when the trigger isunactuated, the spring 8150 can bias the latch 8140 relative to and/oraround the flexible tab(s) 8132 a, 8132 b, such that deflection of thetab(s) 8132 a, 8132 b, and thus engagement with a drive bar 8172, islimited and/or prevented, for example.

In certain instances, the latch 8140 can include a pair oflaterally-opposed nubs 8144, which can slidably engage laterally-opposedbiasing members 8108 of the carriage 8104. Furthermore, in instanceswhere the coupling arrangement 8100 couples more than one drive systembetween the handle 8170 and the surgical end effector, for example, thecarriage 8104 can include multiple biasing members 8108, and/or multiplepairs of biasing members 8108. For example, each socket 8130 can includea pair of laterally positioned nubs 8144, and the carriage 8104 caninclude a biasing member 8108 for each nub 8144, for example.

Referring primarily to FIG. 68 , prior to activation of the trigger 8120and/or upon release of the trigger 8120, the trigger 8120 can bepositioned in the distal, unactuated position, the carriage 8104 can bepositioned in the lifted position relative to the coupler housing 8102,and the latch 8140 can be positioned in the socket-latching position. Insuch an arrangement, the latch 8140 can prevent entry and/or engagementof the drive bar 8172 with the socket 8130, for example. In variousinstances, spring(s) 8150 and/or a different spring and/or biasingmember can bias the trigger 8120 into the unactuated position, thecarriage 8104 into the lifted position, and/or the latch 8140 into thesocket-latching position, for example. To connect and/or attach one ofthe drive bars 8172 to one of the sockets 8130, referring now to FIG. 67, the trigger 8120 can be moved to the proximal, actuated position,which can shift the carriage 8104 to the lowered position, which canshift the latch 8140 to the unlatched position, for example. In such anarrangement, a drive bar 8172 can be configured to enter and/or bereceived by the socket 8130, for example.

Thereafter, if the trigger 8120 is released, referring now to FIG. 68 ,for example, the spring(s) 8150 can bias the trigger 8120 back to thedistal, unactuated position, can bias the carriage 8104 back to thelifted position, and can bias the latch 8140 back to a socket-latchingposition. Accordingly, the drive member 8172 can be locked intoengagement with the socket 8130 because the latch 8140 can preventoutward deflection of the flexible tabs 8132 a, 8132 b, and thus, cansecure the drive member 8172 within the socket 8130, for example.Accordingly, referring now to FIG. 69 , to decouple the drive member8172 from the socket 8130, the trigger 8120 can again be moved to theproximal, actuated position, which can shift the carriage 8104 to thelowered position, which can shift the latch 8140 to the unlatchedposition, for example. In such an arrangement, i.e., when the socket8130 is unlatched, the drive member 8172 can be removed from the socket8130, for example.

In various instances, a surgical instrument can include a drive systemcoupled to a motor. In certain instances, the motor and the drive systemcan affect various surgical functions. For example, the motor and thedrive system can affect opening and/or closing of a surgical endeffector, and can affect a cutting and/or firing stroke, for example. Incertain instances, the motor and drive system can affect multipledistinct surgical functions. For example, opening and closing of thesurgical end effector can be separate and distinct from cutting and/orfiring of fasteners from the surgical end effector. In such instances,the drive system can include a transmission and/or clutch assembly,which can shift engagement of the drive system between different outputsystems, for example.

In various instances, a surgical instrument can include a drive systemhaving multiple output shafts, and a clutch for shifting between thedifferent output shafts. In certain instances, the output shafts cancorrespond to different surgical functions. For example, a first outputshaft can correspond to an end effector closure motion, and a secondoutput shaft can correspond to an end effector firing motion, forexample. In various instances, the drive system can switch betweenengagement with the first output shaft and the second output shaft, forexample, such that the surgical functions are separate and distinctand/or independent. For example, an end effector closure motion can beseparate and distinct from an end effector firing motion. For example,it may be preferable to initiate a closure motion and, upon completionof the closure motion, initiate a separate firing motion. Moreover, itmay be preferable to control and/or drive the independent closure motionand firing motion with a single drive system, which can be coupled to anelectric motor, for example. In other instances, the first output shaftand the second output shaft can be operably coupled and the varioussurgical functions and/or surgical motions can occur simultaneouslyand/or at least partially simultaneously, for example.

Referring now to FIGS. 75-78 , a handle 8600 for a surgical instrumentcan include a drive system 8602, which can include a first output drivesystem 8610 and a second output drive system 8620, for example. Invarious instances, when an end effector is attached to the handle 8600,the first output drive system 8610 can be coupled to a first drivesystem in the attached end effector, and the second output drive system8620 can be coupled to a second drive system in the attached endeffector. The first output drive system 8610 can affect a first surgicalfunction, such as clamping of the end effector jaws, for example, andthe second output drive system 8620 can affect a second surgicalfunction, such as firing of a firing element through the end effector,for example. In other instances, the surgical functions with respect tothe first output drive system 8610 and the second output drive system8620 can be reversed and/or otherwise modified, for example.

In various instances, the drive system 8602 can include a motorassembly, which can include an electric motor 8640 and a motor shaft8642. A drive gear 8644 can be mounted to the motor shaft 8642, forexample, such that the electric motor 8640 drives and/or affectsrotation of the drive gear 8644. In various instances, the first outputdrive system 8610 can include a first drive shaft 8612 and a firstdriven gear 8612. The first driven gear 8614 can be mounted to the firstdrive shaft 8612, for example, such that the rotation of the firstdriven gear 8614 affects the rotation of the first drive shaft 8612. Invarious instances, a linear actuator 8616 can be threadably positionedon the first drive shaft 8612, and rotation of the first drive shaft8612 can affect linear displacement of the linear actuator 8616, forexample. Moreover, in various instances, the second output drive system8620 can include a second drive shaft 8622 and a second driven gear8624. The second driven gear 8624 can be mounted to the second driveshaft 8622, for example, such that the rotation of the second drivengear 8624 affects the rotation of the second drive shaft 8622. Invarious instances, a linear actuator 8626 can be threadably positionedon the second drive shaft 8624, and rotation of the second drive shaft8624 can affect linear displacement of the linear actuator 8626, forexample.

In various instances, the drive system 8602 can further comprise atransmission or shifter assembly 8648. The shifter assembly 8648 can beconfigured to shift engagement of the drive gear 8644 between the firstoutput drive system 8610 and the second output drive system 8620, forexample. For certain instances, the shifter assembly 8648 can include ashifting gear 8652, which can be in meshing engagement with the drivegear 8644, for example. Additionally, the shifting gear 8652 can beconfigured to shift or move between a range of positions, for example,and can remain in meshing engagement with the drive gear 8644 as theshifting gear 8652 moves within the range of positions.

For example, the shifting gear 8652 can move into and/or out ofengagement with at least one of the first driven gear 8614 and/or thesecond driven gear 8624. In various instances, the shifting gear 8652can move into meshing engagement with the second driven gear 8624 of thesecond output drive system 8620. For example, when in a first position(FIG. 78 ) of the range of positions, the shifting gear 8652 can bedisengaged from the second driven gear 8624, and when in a secondposition (FIG. 77 ) of the range of positions, the shifting gear 8652can be engaged with the second driven gear 8624, for example. Ininstances when the shifting gear 8652 is engaged with the second drivengear 8624, the shifting gear 8652 can transfer a force from drive gear8644 to the second driven gear 8624, such that the motor 8640 can affecta surgical function via the second output drive system 8620, forexample. Moreover, in instances when the shifting gear 8652 isdisengaged from the second driven gear 8624, rotation of the motor 8640may not be transferred to the second output drive system 8620, forexample.

In various instances, the shifter assembly 8648 can further comprise anintermediate and/or transfer gear 8654. The transfer gear 8642 can beconfigured to transfer a drive force from the shifting gear 8652 to thefirst driven gear 8614, for example. In various instances, the transfergear 8654 can be in meshing engagement with the first drive gear 8614,for example, such that the rotation of the transfer gear 8654 istransferred to the first driven gear 8614, for example. Moreover, invarious instances the shifting gear 8652 can move into and/or out ofengagement with the transfer gear 8654. For example, when in the firstposition (FIG. 78 ) of the range of positions, the shifting gear 8652can be engaged with the transfer gear 8654, and when in the secondposition (FIG. 77 ) of the range of positions, the shifting gear 8652can be disengaged from the transfer gear 8654, for example. In instanceswhen the shifting gear 8652 is engaged with the transfer gear 8654, theshifting gear 8652 can transfer a force from the drive gear 8644 to thefirst driven gear 8614 via the transfer gear 8654. In such instances,the motor 8640 can affect a surgical function via the first output drivesystem 8610, for example. Moreover, in instances when the shifting gear8652 is disengaged from the transfer gear 8654, rotation of the motor8640 may not be transferred to the first output drive system 8610, forexample.

In various instances, the transfer gear 8654 can be rotatably mounted onthe second drive shaft 8622 of the second output drive system 8620. Forexample, the transfer gear 8654 can be configured to rotate relative tothe second drive shaft 8622 without affecting rotation of the seconddrive shaft 8622 and the second driven gear 8624 fixed thereto. Invarious instances, the shifter assembly 8648 can include a bracket orcollar 8650, which can at least partially surround the shifting gear8652. The bracket 8650 can be positioned around the shifting gear 8652,for example, such that movement of the bracket 8650 can move theshifting gear 8652.

In various instances, the handle 8600 and/or the shifting assembly 8648can further include a trigger or clutch 8630. The clutch 8630 can beconfigured to shift the bracket 8650 and/or the shifting gear 8652within the range of positions. For example, clutch 8630 can comprise atrigger extending from the handle 8600, and can be engaged with thebracket 8650 and/or the shifting gear 8652. In various instances, thebracket 8650 can include a pin 8656, which can extend from the bracket8640 into an aperture 8638 (FIG. 75 ) in the clutch 8630. For example,the clutch 8630 can include an arm 8632 and/or a pair of arms 8632coupled to a pivot point 8634 on the handle 8600. The clutch 8630 canpivot at the pivot point 8634, for example, and pivoting of the arm(s)8632 can move the pin 8656 of the bracket 8560. Movement of the bracket8650 can shift the shifting gear 8652 between the first position (FIG.78 ) and the second position (FIG. 77 ), for example.

In various instances, the movement of the bracket 8650 can beconstrained such that the shifting gear 8652 moves along a longitudinalaxis through its range of positions. Moreover, the pivoting strokeand/or range of movement of the clutch 8630 can be restrained and/orlimited, for example, such that the shifting gear 8652 remains withinthe range of positions as the clutch 8630 pivots. Furthermore, theaperture 8638 (FIG. 75 ) in the clutch 8630 can be configured and/orstructured to maintain and/or hold the shifting gear 8652 within therange of positions and/or in alignment with one of the second drivengear 8624 and/or the transfer gear 8654, for example. In variousinstances, the handle 8600 can include a spring or other biasingmechanism, to bias the shifting gear 8652 into one of the first positionor the second position. In some instances, the handle 8600 can include abistable complaint mechanism configured to hold the shifting gear 8652in its first position or its second position. To the extent that theshifting gear 8652 is between the first position and the secondposition, the bistable compliant mechanism can be dynamically unstableand act to place the shifting gear 8652 in its first position or itssecond position. Alternatively, the shifting gear 8652 can be biasedinto an intermediate position, wherein the shifting gear 8652 can besimultaneously engaged with the first output drive system 8610 and thesecond output drive system 8620, for example. Additionally oralternatively, the handle 8600 can include a lock and/or detent forholding the shifting gear 8652 in one of the first position or thesecond position, for example.

A surgical instrument can include a rotatable drive shaft configured tooperate a closure drive and a firing drive of a surgical instrument.Referring to FIGS. 79-84 , a surgical instrument 10000 can include arotatable drive shaft 10020, a closure drive 10030, and a firing drive10040. As will be described in greater detail below, the drive shaft10020 can include a first thread 10024 configured to operate the closuredrive 10030 and a second thread 10026 configured to operate the firingdrive 10040. In various instances, the instrument 10000 can comprise acircular stapler, for example.

The surgical instrument 10000 can comprise a frame 10002 and means forgenerating a rotary motion. In certain instances, rotary motion can becreated by a manually-driven hand crank, for example, while, in variousinstances, rotary motion can be created by an electric motor. In eitherevent, the generated rotary motion can be transmitted to a rotary inputshaft 10010. Input shaft 10010 can include a proximal bearing portion10011 and a distal bearing portion 10013 which are rotatably supportedby the frame 10002. In various instances, the proximal bearing portion10011 and/or the distal bearing portion 10013 can be directly supportedby the frame 10002 while, in certain instances, the proximal bearingportion 10011 and/or the distal bearing portion 10013 can include abearing positioned between the input shaft 10010 and the frame 10002.The input shaft 10010 can further include a gear 10012 mounted to and/orkeyed to the input shaft 10010 such that, when input shaft 10010 isrotated in direction A (FIG. 79 ), gear 10012 is also rotated indirection A. Correspondingly, when input shaft 10010 is rotated in anopposite direction, i.e., direction A′ (FIG. 82 ), the gear 10012 isalso rotated in direction A′.

Referring primarily to FIGS. 79 and 80 , the drive shaft 10020 caninclude a proximal end 10021 and a distal end 10023. The proximal end10021 and the distal end 10023 can be rotatably supported by the frame10002. In various instances, the proximal end 10021 and/or the distalend 10023 can be directly supported by the frame 10002 while, in certaininstances, the proximal end 10021 and/or the distal end 10023 caninclude a bearing positioned between the drive shaft 10020 and the frame10002. A gear 10022 can be mounted to and/or keyed to the proximal end10021 of the drive shaft 10020. The gear 10022 is meshingly engaged withthe gear 10012 such that, when the input shaft 10010 is rotated indirection A, the drive shaft 10020 is rotated in direction B.Correspondingly, referring to FIG. 81 , when the input shaft 10010 isrotated in direction A′, the drive shaft 10020 is rotated in directionB′.

Referring again to FIG. 79 , the closure drive system 10030 can includea closure pin 10032 engaged with the first thread 10024 of the driveshaft 10020. The closure drive system 10030 can further comprise atranslatable closure member 10033. The closure pin 10032 is positionedwithin an aperture defined in the proximal end of the closure member10033. The closure pin 10032 can include a first end positioned withinthe groove defined by the first thread 10024. When the drive shaft 10020is rotated, a sidewall of the groove can contact the first end of theclosure pin 10032 and displace the closure pin 10032 proximally ordistally, depending on the direction in which the drive shaft 10020 isbeing rotated. For example, when the drive shaft 10020 is rotated indirection B (FIG. 79 ), the closure pin 10032 can be displaced, ortranslated, distally as indicated by direction D. Correspondingly, whenthe drive shaft 10020 is rotated in direction B′ (FIG. 82 ), the closurepin 10032 can be displaced, or translated, proximally as indicated bydirection P. The closure pin 10032 can be closely received within theaperture defined in the closure member 10033 such that the displacement,or translation, of the closure pin 10032 is transferred to the closuremember 10033. As the reader will appreciate, the closure pin 10032 andthe closure member 10033 are constrained from rotating relative to theframe 10002 such that the rotation of the drive shaft 10020 is convertedto the translation of the closure pin 10032 and the closure member10033.

Referring primarily to FIG. 80 , the first thread 10024 extends along afirst length 10025 of the drive shaft 10020. In certain instances, thefirst thread 10024 may extend along the entire length of the drive shaft10020 while, in other circumstances, the first thread 10024 may extendalong less than the entire length of the drive shaft 10020. The firstthread 10024 can include a proximal portion adjacent the proximal end10021 of the drive shaft 10020 and a distal portion adjacent the distalend 10023 of the drive shaft 10020. When the closure pin 10032 is in thedistal portion of the first thread 10024, as illustrated in FIG. 81 ,the closure member 10033 can position an anvil of the surgicalinstrument 10000 in an open position. As the drive shaft 10020 isrotated in direction B′, the closure pin 10032 can translate proximallyuntil the closure pin 10032 reaches the proximal portion of the firstthread 10024, as illustrated in FIG. 82 . As the closure pin 10032 movesproximally, the closure pin 10032 can pull the closure member 10033 andthe anvil proximally. When the closure pin 10032 reaches the proximalportion of the first thread 10024, the anvil can be in a fully closedposition.

Further to the above, the closure drive 10030 can be operated to movethe anvil of the surgical instrument 10000 into a suitable positionrelative to a staple cartridge. In various instances, the surgicalinstrument 10000 can include an actuator which can be operated in afirst direction to rotate the input shaft 10010 in direction A and thedrive shaft 10020 in direction B and a second direction to rotate theinput shaft 10010 in direction A′ and the drive shaft 10020 in directionB′. In other instances, the surgical instrument 10000 can include afirst actuator configured to rotate the input shaft 10010 in direction Aand the drive shaft 10020 in direction B, when operated, and a secondactuator configured to rotate the input shaft 10010 in direction A′ andthe drive shaft 10020 in direction B′, when operated. In either event,an operator of the surgical instrument 10000 can move the anvil of thesurgical instrument 10000 toward and away from the staple cartridge, asneeded, in order to create a desired gap between the anvil and thestaple cartridge. Such a desired gap may or may not be created when theanvil is in its fully closed position.

Further to the above, the surgical instrument 10000 can include a catchconfigured to receive and releasably hold the drive pin 10032 when theclosure system 10030 has reached its fully closed configuration.Referring primarily to FIGS. 81 and 82 , the surgical instrument 10000can include a catch bar 10073 comprising a catch aperture 10077 definedtherein. As the drive pin 10032 is advanced proximally, the drive pin10032 can become aligned with, and then at least partially enter, thecatch aperture 10077. The catch pin 10032 can be biased toward the catchbar 10073 by a spring 10035 positioned intermediate the closure member10033 and a circumferential head 10037 extending around the catch pin10032. When the catch pin 10032 is positioned distally with respect tothe catch aperture 10077, the spring 10035 can bias the drive pin 10032against the catch bar 10073. When the catch pin 10032 is movedproximally by the rotation of the drive screw 10020 and becomes alignedwith the catch aperture 10077, the spring 10035 can move the drive pin10032 upwardly into the catch aperture 10077. The drive pin 10032 can bemoved upwardly by the spring 10035 until the head of the drive pin 10032contacts the catch bar 10073. Notably, the movement of the drive pin10032 toward the catch aperture 10077 can cause the drive pin 10032 tobecome operably disengaged from the first thread 10024. Thus, theclosure system 10030 can become deactivated when the drive pin 10032reaches the catch aperture 10077 such that subsequent rotation of thedrive shaft 10020 does not move the drive pin 10032, the closure member10033, and the anvil operably engaged therewith, at least until thedrive pin 10032 is re-engaged with the first thread 10024 as describedin greater detail further below.

As discussed above, the entry of the drive pin 10032 into the catchaperture 10077 of the catch bar 10073 can demarcate the end of theclosing stroke of the closure system 10030 and the fully closed positionof the anvil. In various instances, the catch bar 10073 may not bemovable relative to the frame 10002 and the catch aperture 10077 maydemarcate a fixed position. In other instances, the catch bar 10073 maybe movable relative to the frame 10002. In such instances, the final,closed position of the anvil will depend on the position of the catchaperture 10077. As a result, the gap between the anvil and the staplecartridge of the surgical instrument 10000 will depend on the positionof the catch aperture 10077. Referring generally to FIG. 79 , thesurgical instrument 10000 can further comprise a gap setting system10070 configured to move the catch bar 10073. The gap setting system10070 can comprise a rotatable knob 10072 and a drive gear 10071 engagedwith the rotatable knob 10072. The catch bar 10073 can include a rack10075 extending therefrom which comprises a plurality of teeth. Thedrive gear 10071 is meshingly engaged with the rack 10075 such that,when the knob 10072 is rotated in a first direction, the rack 10075 candrive the catch bar 10073 distally and, when the knob 10072 is rotatedin a second direction opposite the first direction, the rack 10075 candrive the catch bar 10073 proximally. When the catch bar 10073 is moveddistally, the catch aperture 10077 can be positioned such that a largergap between the anvil and the staple cartridge may be present when theclosure drive 10030 is in its fully closed position. When the catch bar10073 is moved proximally, the catch aperture 10077 can be positionedsuch that a smaller gap between the anvil and the staple cartridge maybe present when the closure drive 10030 is in its fully closed position.In various instances, the catch aperture 10077 can be positionablewithin a range of positions which can accommodate a range of distancesbetween the anvil and the staple cartridge of the surgical instrument10000.

In various instances, the gap setting system 10070 can comprise a knoblock configured to releasably hold the knob 10072 in position. Forinstance, the frame 10002 can include a lock projection 10004 extendingtherefrom which can be received within one or more lock apertures 10074defined in the knob 10072. The lock apertures 10074 can be positionedalong a circumferential path. Each lock aperture 10074 can correspondwith a preset position of the closure drive 10030 and a preset gapdistance between the anvil and the staple cartridge of the surgicalinstrument 10000. For instance, when the lock projection 10004 ispositioned in a first lock aperture 10074, the closure drive 10030 canbe held in a first preset position and, correspondingly, the anvil canbe held a first preset distance from the staple cartridge. In order tomove the knob 10072 into a second preset position, the knob 10072 can belifted away from the frame 10002 such that lock projection 10004 is nolonger positioned in the first lock aperture 10074, rotated to drive therack 10075 and the catch bar 10073, and then moved toward the frame10002 such that the lock projection 10004 enters into a second lockaperture 10074 defined in the knob 10072. When the lock projection 10004is positioned in the second lock aperture 10074, the closure drive 10030can be held in a second preset position and, correspondingly, the anvilcan be held a second preset distance from the staple cartridge which isdifferent than the first preset distance. In order to move the knob10072 into a third preset position, the knob 10072 can be lifted awayfrom the frame 10002 such that lock projection 10004 is no longerpositioned in the first or second lock aperture 10074, rotated to drivethe rack 10075 and the catch bar 10073, and then moved toward the frame10002 such that the lock projection 10004 enters into a third lockaperture 10074 defined in the knob 10072. When the lock projection 10004is positioned in the third lock aperture 10074, the closure drive 10030can be held in a third preset position and, correspondingly, the anvilcan be held a third preset distance from the staple cartridge which isdifferent than the first and second preset distances. The gap settingsystem 10070 can further include a biasing element configured to biasthe knob 10072 toward the frame 10002. For instance, the gap settingsystem 10070 can include a spring 10076 positioned intermediate thehousing 10002 and the drive gear 10071, for example, configured to biasa lock aperture 10074 into engagement with the lock projection 10004.

In certain instances, an operator of the surgical instrument 10000 maybe able to discern the position of the closure system 10030 by observingthe position of the anvil. In some instances, however, the anvil may notbe visible in a surgical field. Referring primarily to FIG. 79 , thesurgical instrument 10000 can further comprise an anvil positionindicator system 10050 configured to indicate the position of the anvil.The anvil position indicator system 10050 can include a window 10058defined in the frame 10002 and a pivotable member 10051 observablethrough the window 10058. The pivotable member 10051 can include a pivot10052 rotatably mounted to the frame 10002, a drive end 10054, and adisplay end 10056. The pivotable member 10051 can be movable between afirst position (FIG. 81 ) which indicates that the anvil is in a fullyopen position, a second position (FIG. 82 ) which indicates that theanvil is in a fully closed position, and a range of positions betweenthe first position and the second position which represent a range ofpositions of the anvil. The closure system 10030 can be configured tocontact the drive end 10054 of the pivotable member 10051 to move thepivotable member 10051. When the drive pin 10032 is moved proximally bythe drive shaft 10020, referring primarily to FIG. 82 , the drive pin10032 can pull the closure member 10033 proximally such that a shoulder10036 defined on the closure member 10033 can contact the drive end10054 of the pivotable member 10051 and rotate the pivotable member10051 about the pivot 10052. The rotation of the pivotable member 10051can move the display end 10056 within the window 10058 to indicate theposition of the anvil. To facilitate this observation, the frame 10002and/or the window 10058 can include one or more demarcations 10059 whichcan indicate the position of the anvil. For instance, when the displayend 10056 of the pivotable member 10051 is aligned with a proximaldemarcation 10059 (FIG. 81 ), the operator can determine that the anvilis in an open position and, when the display end 10056 is aligned with adistal demarcation 10059 (FIG. 82 ), the operator can determine that theanvil is in a closed position. If the display end 10056 is positionedintermediate the proximal and distal demarcations 10059, the operatorcan assume that the anvil is in a position between its open position andits closed position. Additional demarcations 10059 between the proximaland distal demarcations 10059 can be utilized to indicate additionalpositions of the anvil. When the closure member 10033 is moved distallyto open the anvil (FIG. 84 ), the pivotable member 10051 can rotate backinto its first position and become aligned with the proximal demarcation10059 once again. The position indicator system 10050 can furtherinclude a biasing member, such as a spring, for example, configured tobias the pivotable member 10051 into its first position.

As discussed above, the closure system 10030 of the surgical instrument10000 can be operated to position the anvil of the surgical instrument10000 relative to the staple cartridge. During the operation of theclosure system 10030, the firing system 10040 may not be operated. Thefiring system 10040 may not be operably engaged with the drive shaft10020 until after the closure drive 10030 has reached its fully closedposition. The surgical instrument 10000 can include a switch, such asswitch 10060, for example, configured to switch the surgical instrumentbetween an anvil closure operating mode and a staple firing operatingmode. The closure drive 10030 can further comprise a switch pin 10031extending from the proximal end of the closure member 10033. Uponcomparing FIGS. 81 and 82 , the reader will appreciate that the switchpin 10031 comes into contact with the switch 10060 as the closure pin10032 is being advanced proximally to close the anvil. The switch 10060can be pivotably mounted to the frame 10002 about a pivot 10062 and caninclude one or more arms 10064 extending therefrom. The switch pin 10031can contact the arms 10064 and rotate the switch 10060 about the pivot10062 when the drive pin 10032 reaches its fully closed position. Theswitch 10060 can further comprise an arm 10066 extending therefrom whichcan be configured to push a firing nut 10042 of the firing drive 10040into operative engagement with the drive shaft 10020 when the switch10060 is rotated about pivot 10062. More particularly, in at least onecircumstance, the arm 10066 can be configured to displace a push bar10044 distally which can, in turn, push the firing nut 10042 onto thesecond thread 10026. At such point, the drive pin 10032 and the closuresystem 10030 may be disengaged from the first thread 10024, as a resultof the catch aperture 10077 described above, and the firing nut 10042and the firing system 10040 can be engaged with the second thread 10026.

Further to the above, the firing nut 10042 can comprise a threadedaperture 10041 defined therein which can be threadably engaged with thesecond thread 10026. When the closure drive 10030 is being operated,further to the above, the firing nut 10042 may be positioned proximallywith respect to the second thread 10026 such that the threaded aperture10041 is not threadably engaged with the second thread 10026. In suchcircumstances, the firing nut 10042 may sit idle while the drive shaft10020 is rotated to operate the closure system 10030. When the firingnut 10042 is displaced distally, further to the above, the threadedaperture 10041 can become threadably engaged with the second thread10026. Once the firing nut 10042 is threadably engaged with the secondthread 10026, rotation of the drive shaft 10020 in direction B′ (FIG. 82) will displace the firing nut 10042 distally. The firing nut 10042 caninclude one or more anti-rotation features, such as flanges 10043, forexample, which can be slidably engaged with the frame 10002 to preventthe firing nut 10042 from rotating with the drive shaft 10020. Thefiring drive 10040 can further include a firing member coupled to thefiring nut 10042 which can be pushed distally by the firing nut 10042.The firing member can be configured to eject staples from the staplecartridge. When the firing nut 10042 reaches the distal end of thesecond thread 10026, the firing nut 10042 may become threadablydisengaged from the second thread 10026 wherein additional rotation ofthe drive shaft 10020 in direction B′ may no longer advance the firingnut 10042.

Referring primarily to FIGS. 82 and 83 , the surgical instrument 10000can further comprise a reverse activator 10047 positioned at the distalend of the second thread 10026. The firing nut 10042 can be configuredto contact the reverse actuator 10047 and displace the reverse actuator10047 distally when the firing nut 10042 reaches the distal end of thesecond thread 10026. A biasing member, such as spring 10048, forexample, can be positioned intermediate the reverse actuator 10047 andthe frame 10002 which can be configured to resist the distal movement ofthe reverse actuator 10047. The distal movement of the reverse actuator10047 can compress the spring 10048, as illustrated in FIG. 83 , andapply a proximal biasing force to the firing nut 10042. When the driveshaft 10020 is rotated in direction B, the proximal biasing forceapplied to firing nut 10042 can re-engage the threaded aperture 10041 ofthe firing nut 10042 with the second thread 10026 and the firing nut10042 can be moved proximally, as illustrated in FIG. 84 . The proximalmovement of the firing nut 10042 can move the firing member proximally.When moving proximally, the firing nut 10042 can displace the push bar10044 such that the push bar 10044 contacts the arm 10066 of the switch10060 and rotates the switch 10060 in an opposite direction back intoits unswitched position. At such point, the firing nut 10042 may becomethreadably disengaged from the second thread 10026 and further rotationof drive shaft 10020 in direction B may no longer displace the firingnut 10042 proximally. At such point, the firing nut 10042 will haveresumed its idle position.

When the switch 10060 is rotated back into its original position,further to the above, the arms 10064 of the switch 10060 can push theswitch pin 10031 and the closure member 10033 distally. The distalmovement of the switch pin 10031 and the closure member 10033 candisplace the drive pin 10032 from the catch aperture 10077 defined inthe catch bar 10073. As the drive pin 10032 exits the catch aperture10077, the drive pin 10032 can move downwardly against the biasing forceof the spring 10035 in order to slide under the catch bar 10073. Thedownward movement of the drive pin 10032 can re-engage the drive pin10032 with the first thread 10024. Further rotation of the drive shaft10020 in direction B will displace the drive pin 10032 and the closuremember 10033 distally to open the anvil of the surgical instrument10000. At such point, the surgical instrument 10000 will have been resetfor a subsequent use thereof. In various instances, the staple cartridgecan be replaced and/or reloaded and the surgical instrument 10000 can beused once again.

As the reader will appreciate from the above, the drive screw 10020 candisplace the drive pin 10032 to operate the closure drive 10030 and thefiring nut 10042 to operate the firing drive 10040. Further to theabove, the drive screw 10020 can displace the drive pin 10032 along afirst length 10025 of the drive screw 10020. Similarly, the drive screw10020 can displace the firing nut 10042 along a second length 10027 ofthe drive screw 10020. The first length 10025 can define a closurestroke of the closure system 10030 and the second length 10027 candefine a firing stroke of the firing stroke 10040. The first length10025 can be longer than the second length 10027, although the secondlength 10027 could be longer than the first length 10025 in certaincircumstances. In use, the closure pin 10032 can pass by the firing nut10042. For instance, when the closure pin 10032 is moved proximally toclose the anvil, the closure pin 10032 can pass by the firing nut 10042when the firing nut 10042 is in its idle position. Similarly, theclosure pin 10032 can pass by the firing nut 10042 in its idle positionwhen the closure pin 10032 is moved distally to open the anvil. In orderto facilitate this relative movement, the firing nut 10042 can includean opening, such as slot 10046, for example, defined therein throughwhich the closure pin 10032 can pass as the closure pin 10032 movesrelative to the firing nut 10042. Such an opening defined in the firingnut 10042 could also permit the firing nut 10042 to slide by the closurepin 10032 in various other embodiments.

Further to the above, the first length 10025 and the second length 10027can at least partially overlap. Moreover, the first thread 10024 and thesecond thread 10026 can at least partially overlap. The first thread10024 and the second thread 10026 can be defined on the same portion ofthe drive screw 10020. The first thread 10024 and the second thread10026 can be sufficiently dissimilar such that the closure pin 10032does not follow the second thread 10026 and such that the firing nut10042 does not follow the first thread 10024. For instance, the firstthread 10024 can include a first thread pitch and the second thread10026 can include a second thread pitch which is different than thefirst thread pitch. The first thread pitch of the first thread 10024 mayor may not be constant. In the event that the first thread pitch isconstant, the closure pin 10032 and the anvil operably engaged with thefirst thread 10024 will move at a constant speed throughout the closurestroke for a given rotational speed of the drive shaft 10020. In theevent that the first thread pitch is not constant, the closure pin 10032and the anvil will move at different speeds during the closure strokefor a given rotational speed of the drive shaft 10020. For instance, thedistal portion of the first thread 10024 can include a thread pitchwhich is greater than the thread pitch of the proximal portion of thefirst thread 10024. In such circumstances, the anvil will move quicklyaway from its open position and move slower once it nears its closedposition for a given rotational speed of the drive shaft 10020. Such anarrangement would permit the anvil to be moved quickly into positionagainst tissue positioned intermediate the anvil and the staplecartridge and then slower once the anvil was engaged with the tissue inorder to mitigate the possibility of over-compressing the tissue. Invarious other instances, the distal portion of the first thread 10024can include a thread pitch which is less than the thread pitch of theproximal portion of the first thread 10024. In either event, the threadpitch can change between the ends of the first thread 10024. This changecan be linear and/or non-linear.

Further to the above, the second thread pitch of the second thread 10026may or may not be constant. In the event that the second thread pitch isconstant, the firing nut 10042 and the firing member operably engagedwith the second thread 10026 will move at a constant speed throughoutthe closure stroke for a given rotational speed of the drive shaft10020. In the event that the second thread pitch is not constant, thefiring nut 10042 and the firing member will move at different speedsduring the firing stroke for a given rotational speed of the drive shaft10020. For instance, the distal portion of the second thread 10026 caninclude a thread pitch which is less than the thread pitch of theproximal portion of the second thread 10026. In such circumstances, thefiring member will move slower at the end of its firing stroke for agiven rotational speed of the drive shaft 10020. Such an arrangementwould slow the firing member down as it reached the end of the stapleforming process. Moreover, such an arrangement could generate a largeramount of torque at the end of the firing stroke which correlates withthe completion of the staple forming process. In various otherinstances, the distal portion of the second thread 10026 can include athread pitch which is greater than the thread pitch of the proximalportion of the second thread 10026. In either event, the thread pitchcan change between the ends of the second thread 10026. This change canbe linear and/or non-linear.

Turning now to FIGS. 86-93 , a surgical instrument 10500 can include ashaft 10504 and an end effector 10505. The end effector 10505 caninclude a staple cartridge 10506 and a movable anvil 10508. The surgicalinstrument 10500 can include a closure drive including a closure memberoperably engageable with the anvil 10504 and a firing drive including afiring member configured to deploy staples from the staple cartridge10506. The surgical instrument 10500 can include means for generating arotary motion such as a hand crank and/or an electric motor, forexample. The rotary motion can be transmitted to an input shaft 10510.The surgical instrument 10500 can include a transmission 10502 which isconfigured to selectively transmit the rotation of the input shaft 10510to the closure drive and to the firing drive, as discussed in greaterdetail further below.

The input shaft 10510 can include a input gear 10512 mounted and/orkeyed thereto which rotates with the input shaft 10510. The input shaft10510 can be rotatably supported by a frame of the surgical instrument10500 by a proximal end 10511 and a distal end 10519. The input gear10512 can be meshingly engaged with an intermediate gear 10522 mountedand/or keyed to an intermediate shaft 10520. Thus, when input shaft10510 and input gear 10512 are rotated in direction A (FIG. 89 ),intermediate shaft 10520 and intermediate gear 10522 are rotated indirection B (FIG. 89 ). Similar to the above, the intermediate shaft10520 can be rotatably supported by the surgical instrument frame by aproximal end 10521 and a distal end 10529. The intermediate shaft 10520can further include a threaded portion 10524 which can be threadablyengaged with a shifter block 10526. Referring primarily to FIG. 87 , theshifter block 10526 can include one or more threaded apertures 10527threadably engaged with the threaded portion 10524. When theintermediate shaft 10520 is rotated in direction B, referring primarilyto FIG. 89 , the intermediate shaft 10520 can displace the shifter block10526 proximally.

Further to the above, the shifter block 10526 can include a gear slot10528 defined therein. The input shaft 10510 can further include aslider gear 10516 slidably mounted thereto which is positioned in thegear slot 10528. When the shifter block 10526 is moved proximally by theintermediate shaft 10520, as discussed above, the shifter block 10526can push the slider gear 10516 proximally along a keyed input shaftportion 10514. Referring primarily to FIG. 87 , the slider gear 10516can include an aperture 10517 defined therein including one or more flatsurfaces, for example, which are aligned with corresponding flatsurfaces on the keyed input shaft portion 10514. The flat surfaces ofthe aperture 10517 and the keyed input shaft portion 10514 can permitthe slider gear 10516 to be slid longitudinally along the input shaft10510 and, in addition, co-operate to transmit rotational motion betweenthe slider gear 10516 and the input shaft 10510. As will be described ingreater detail below, the shifter block 10526 can slide the slider gear10516 through a first range of positions in which the slider gear 10516is engaged with a closure shaft 10530, a second range of positions inwhich the slider gear 10516 is engaged with a firing shaft 10540, and anull position, or a range of null positions, intermediate the firstrange and the second range of positions in which the slider gear 10516is not engaged with either the closure shaft 10530 or the firing shaft10540.

Further to the above, FIG. 85 depicts the anvil 10508 of the endeffector 10505 in a fully closed position and a firing driver 10548 inan unfired position. FIG. 86 depicts the transmission 10502 in aconfiguration which is consistent with the configuration of the endeffector 10505 depicted in FIG. 85 . More particularly, the slider gear10516 is in its null, or idle, position and is not operably engaged witha closure shaft 10530 of the closure drive or a firing shaft 10540 ofthe firing drive. When the slider gear 10516 is in its idle position,the slider gear 10516 is positioned intermediate a closure gear 10532mounted and/or keyed to the closure shaft 10530 and a firing gear 10542mounted and/or keyed to the firing shaft 10540. Moreover, the slidergear 10516 is not engaged with the closure gear 10532 or the firing gear10542 when the slider gear 10516 is in its idle position. In order tomove the anvil 10508 into its open position, and/or detach the anvil10508 from the end effector 10505, as illustrated in FIG. 88 , the inputshaft 10510 can be rotated in direction A, as illustrated in FIG. 89 .As discussed above, the rotation of input shaft 10510 in direction A canrotate the intermediate shaft 10520 in direction B and move shifterblock 10526 proximally. When the shifter block 10526 moves proximally,the shifter block 10526 can push the slider gear 10516 into operativeengagement with the closure gear 10532. At such point, the continuedrotation of input shaft 10510 in direction A can be transmitted to theclosure shaft 10530 via the meshingly engaged slider gear 10516 andclosure gear 10532. When the slider gear 10516 is meshingly engaged withthe closure gear 10532, the rotation of the input shaft 10510 indirection A will rotate the output shaft 10530 in direction C, asillustrated in FIG. 89 . The closure drive can further include a closurenut 10536 comprising a threaded aperture 10537 defined therein which isthreadably engaged with a threaded portion 10534 of the closure shaft10530. The closure nut 10536 can include one or more anti-rotationfeatures slidably engaged with the frame of the surgical instrument, forexample, which can prevent the closure nut 10536 from rotating with theclosure shaft 10530 such that the rotational movement of the closureshaft 10530 can be converted to longitudinal movement of the closure nut10536. The closure system can further include a closure member 10538extending from the closure nut 10536 which can be engaged with the anvil10508. When the closure shaft 10530 is rotated in direction C, referringagain to FIG. 89 , the closure nut 10536 and the closure member 10538can be advanced distally to move the anvil 10508 into an open position.

Further to the above, FIG. 89 depicts the transmission 10502 in aclosure configuration, i.e., a configuration in which the anvil 10508can be opened and closed. When the slider gear 10516 is meshinglyengaged with the closure gear 10532, the input shaft 10510 will directlydrive the closure shaft 10530. Concurrently, the input shaft 10510 willdirectly drive the intermediate shaft 10520 owing to the meshingengagement between the input gear 10512 and the intermediate gear 10522.Also, when the slider gear 10516 is meshingly engaged with the closuregear 10532, the slider gear 10516 is not meshingly engaged with thefiring gear 10542 and, as such, the input shaft 10510 will not drive thefiring shaft 10540 when the transmission 10502 is in the closureconfiguration.

Once the anvil 10508 has been moved into an open position and/ordetached from the closure member 10538, further to the above, tissue canbe positioned intermediate the anvil 10508 and the staple cartridge10506. Thereafter, referring to FIGS. 90 and 91 , the anvil 10508 can bemoved into its closed position by rotating the input shaft 10510 in anopposite direction, i.e., direction A′, which will rotate the closureshaft 10530 in an opposite direction, i.e., direction C′, in order tomove the closure nut 10536, the closure member 10538, and the anvil10508 proximally. The input shaft 10510 will also rotate intermediateshaft 10520 in an opposite direction, i.e., direction B′, when the inputshaft 10510 is rotated in direction A′. When the intermediate shaft10520 is rotated in direction B′, the intermediate shaft 10520 willdisplace the shifter block 10526 and the slider gear 10516 distally. Theshifter block 10526 can push the slider gear 10516 distally until theslider gear 10516 is no longer meshingly engaged with the closure gear10532 and the slider gear 10516 has been returned to its idle position.Additional rotation of the intermediate shaft 10520 in direction B′ willcause the shifter block 10526 to displace the slider gear 10516 distallyuntil the slider gear 10516 is meshingly engaged with the firing gear10542. At such point, referring to FIGS. 92 and 93 , the input shaft10510 can directly drive the firing shaft 10540. Thereafter, the inputshaft 10510 can rotate the firing shaft 10540 in direction D′ when theinput shaft 10510 is rotated in direction A′. The firing system canfurther comprise a firing nut 10546 including a threaded aperture 10547which is threadably engaged with a threaded portion 10544 of the firingshaft 10540. When the firing shaft 10410 is rotated in direction A′, thefiring shaft 10540 can advance the firing nut 10546 distally. The firingnut 10546 can include one or more anti-rotation features which can beslidably engaged with the frame of the surgical instrument such that thefiring nut 10546 does not rotate with the firing shaft 10540 and suchthat rotational movement of the firing shaft 10540 can be converted tolongitudinal movement of the firing nut 10546. The firing drive canfurther include a firing member 10548 extending from the firing nut10546 which is advanced distally to eject staples from the staplecartridge 10506. Throughout the firing stroke of the firing system, theshifter block 10526 can continue to advance the slider gear 10516distally. The firing stroke can be completed when the shifter block10526 advances slider gear 10516 distally to the point in which theslider gear 10516 is no longer threadably engaged with the firing gear10542. At such point, the firing member 10548 may be in its fully firedposition.

Further to the above, FIG. 93 depicts the transmission 10502 in a firingconfiguration, i.e., a configuration in which the firing member 10548can be advanced or retracted. When the slider gear 10516 is meshinglyengaged with the firing gear 10542, the input shaft 10510 will directlydrive the firing shaft 10540. Concurrently, the input shaft 10510 willdirectly drive the intermediate shaft 10520 owing to the meshingengagement between the input gear 10512 and the intermediate gear 10522.Also, when the slider gear 10516 is meshingly engaged with the firinggear 10542, the slider gear 10516 is not meshingly engaged with theclosure gear 10532 and, as such, the input shaft 10510 will not drivethe closure shaft 10530 when the transmission 10502 is in the firingconfiguration.

In order to retract the firing member 10548, the input shaft 10510 canbe rotated in direction A to rotate intermediate shaft 10520 indirection B, displace the shifter block 10526 proximally, and re-engagethe slider gear 10516 with the firing gear 10542. At such point, thecontinued rotation of input shaft 10510 in direction A will rotate thefiring shaft 10540 in an opposite direction to direction D′, displacethe firing nut 10546 proximally, and retract the firing member 10548. Asthe slider gear 10516 is rotating the firing gear 10542, the shifterblock 10526 can continue to pull the slider gear 10516 proximally untilthe slider gear 10516 is no longer meshingly engaged with the firinggear 10542 and the slider gear 10516 reaches its idle position. At suchpoint, the continued rotation of input shaft 10510 in direction A willcontinue to displace the shifter block 10526 and the slider gear 10516proximally and re-engage the slider gear 10516 with the closure gear10532 in order to re-open the anvil 10508.

FIGS. 94-98 illustrates a surgical instrument 11010 configured to stapleand/or incise tissue. Surgical instrument 11010 can include apistol-grip shaped handle 11015. Handle 11015 includes a first handleportion 11020 defining a longitudinal axis 11030 from which jaws 11070and 11090 can extend. Handle 11015 includes a second handle portion,i.e., handle grip 11040, which defines a second portion axis 11050.Second portion axis 11050 defines an angle 11060 with longitudinal axis11030. In various instances, angle 11060 can comprise any suitableangle, such as about 120 degrees, for example. The jaw 11070 cancomprise a cartridge channel including an opening configured toremovably receive a staple cartridge 11080. The staple cartridge 11080can include a plurality of staples removably stored within staplecavities arranged in at least two longitudinal rows, one on either sideof a channel in which a knife for transecting tissue can travel, asdescribed in greater detail below. In at least on instance, threelongitudinal rows of staple cavities can be arranged on a first side ofthe knife channel while three longitudinal rows of staple cavities canbe arranged on a second side of the knife channel. The jaw 11090 cancomprise an anvil rotatable to a position in opposition to and alignmentwith the staple cartridge 11080 so that anvil pockets defined in theanvil 11090 can receive and form staples ejected from the staplecartridge 11080. FIG. 98 depicts the anvil 11090 in an open positionwhile FIG. 94 depicts the anvil 11090 in a closed position. Although notillustrated, other embodiments are envisioned in which the jaw includingthe staple cartridge 11080 is rotatable relative to the anvil 11090. Inany event, as will be described in greater detail below, the handle11015 can further include a closure button 11065 (FIG. 98 ) configuredto operate a closure system which moves the anvil 11090 between its openand closed positions and a firing button 11055 configured to operate afiring system which ejects the staples from the staple cartridge 11080.The closure button 11065 can be positioned and arranged on the handle11015 such that it can be easily accessed by the thumb of the operator'shand which is supporting the handle 11015, for example, while the firingbutton 11055 can be positioned and arranged such that it can be easilyaccessed by the index finger of the operator's handle which issupporting the handle 11015.

Further to the above, the anvil 11090 can be moved toward and away fromthe staple cartridge 11080 during use. In various instances, the closurebutton 11065 can include a bi-directional switch. When the closurebutton 11065 is depressed in a first direction, the closure system ofthe surgical instrument 11010 can move the anvil 11090 toward the staplecartridge 11080 and, when the closure button 11065 is depressed in asecond direction, the closure system can move the anvil 11090 away fromthe staple cartridge 11080. Referring primarily to FIGS. 95 and 97 , theclosure system can include a closure motor 11110 configured to move theanvil 11090. The closure motor 11110 can include a rotatable closureshaft 11130 extending therefrom to which a first closure gear 11140 canbe affixed. The closure motor 11110 can rotate the closure shaft 11130and the closure shaft 11130 can rotate the first closure gear 11140. Thefirst closure gear 11140 can be meshingly engaged with an idler gear11150 which, in turn, can be meshingly engaged with a closure lead screwdrive gear 11160. Closure lead screw drive gear 11160 is affixed to aclosure lead screw 11170. When the first closure gear 11140 is rotatedby the closure shaft 11130, the first closure gear 11140 can rotate theidler gear 11150, the idler gear 11150 can rotate the closure lead screwdrive gear 11160, and the closure lead screw drive gear 11160 can rotatethe closure lead screw 11170.

Referring primarily to FIG. 97 , the closure shaft 11130, the firstclosure gear 11140, the idler gear 11150, and the closure lead screwdrive gear 11160 can be rotatably supported by a motor block 11125supported within the handle portion 11120. The closure lead screw 11170can include a first end which is also rotatably supported by the motorblock 11125 and/or a second end which is rotatably supported by thehousing of the handle 11015. The closure lead screw 11170 can furthercomprise a threaded portion intermediate the first end and the secondend. The closure system can further comprise a closure block 11175 (FIG.96 ) which can include a threaded aperture 11176 which is threadablyengaged with the threaded portion of the closure lead screw 11170. Theclosure block 11175 can be constrained from rotating with the closurelead screw 11170 such that, when the closure lead screw 11170 isrotated, the closure lead screw 11170 can displace the closure block11175 proximally or distally, depending on the direction in which theclosure lead screw 11170 is being rotated. For instance, if the closurelead screw 11170 is rotated in a first direction, the closure lead screw11170 can displace the closure block 11175 distally and, when theclosure lead screw 11170 is rotated in a second, or opposite, direction,the closure lead screw 11170 can displace the closure block 11175proximally. Referring primarily to FIG. 96 , the closure block 11175 canbe mounted to a latch member in the form of closure channel 11180, whichtranslates along the outside of cartridge channel 11170. In variousinstances, the closure channel 11180 can be enclosed within the handleportion 11120 while, in some instances, the closure channel 11180 canprotrude from the handle portion 11120. Closure channel 11180 cancomprise an approximately “U” shaped channel when viewed from the endand can include opposing sidewalls 11182. Each sidewall 11182 caninclude a cam slot 11190 defined therein. As described in greater detailfurther below, the cam slots 11190 can be configured to engage the anvil11090 and move the anvil 11090 relative to the staple cartridge 11080.

Further to the above, the closure channel 11180 fits around thecartridge channel 11070 so that cartridge channel 11070 nests inside the“U” shape of the closure channel 11180. Referring primarily to FIG. 96 ,the cartridge channel 11070 can include elongated slots 11195 definedtherein and the closure channel 11180 can include pins which extendinwardly into the elongated slots 11195. The closure channel pins andthe elongated slots 11195 can constrain the movement of the closurechannel 11180 such that closure channel 11180 translates relative to thecartridge channel 11070 along a longitudinal path. The translationalmovement of the closure channel 11180 can rotate the anvil 11090. Theanvil 11090 can be connected to the closure channel 11180 via a distalclosure pin 11210 which extends through anvil cam holes 11211 defined inthe anvil 11090 and the cam slots 11190 defined in the closure channel11180. Each cam slot 11190 can include a first, or distal, end 11191 anda second, or proximal, end 11192. Each cam slot 11190 can furtherinclude a first, or proximal, drive surface 11193 and a second, ordistal, drive surface 11194. When the closure system is in its openconfiguration and the anvil 11090 is in its open position, the closurechannel 11180 can be in its first, or unadvanced, position and thedistal closure pin 11210 can be in the first, or distal, ends 11191 ofthe cam slots 11190. When the closure channel 11180 is advanced distallyto move the anvil 11090 toward the staple cartridge 11080, the firstdrive surface 11193 can contact the distal closure pin 11210 and pushthe distal closure pin 11210 downwardly toward the staple cartridge11080. When the closure system is in its closed configuration and theanvil 11090 is in its closed position opposite the staple cartridge11080, the closure channel 11180 can be in its second, or completelyadvanced, position and the distal closure pin 11210 can be in thesecond, proximal ends 11192 of the cam slots 11190.

Each cam slot 11190 can comprise a curved, or arcuate, path. The firstdrive surface 11193 can comprise a first arcuate surface and the seconddrive surface 11194 can comprise a second arcuate surface. In variousinstances, each cam slot 11190 can include at least one curved portionand at least linear portion. In at least one instance, each first drivesurface 11193 can comprise a flat surface in a distal end 11191 of a camslot 11190. The flat surface can comprise a vertical surface which isperpendicular to, or at least substantially perpendicular to, thelongitudinal axis 11030 of the instrument 11010. Such a flat surface canact as a detent which would require an initial amount of force todisplace the closure pin 11210 into the arcuate portion of the cam slot11190. In certain instances, each first drive surface 11193 can comprisea flat surface 11196 in a proximal end 11192 of a cam slot 11190. Eachflat surface 11196 can comprise a horizontal surface which is parallelto, or at least substantially parallel to, the longitudinal axis 11030.The flat surfaces 11196 can provide a large mechanical advantage betweenthe closure channel 11180 and the anvil 11090. In various instances, thefirst drive surfaces 11193 can apply very little mechanical advantage tothe closure pin 11210 when the closure pin 11210 is in the distal ends11191 of the slots 11190; however, as the closure pin 11210 slidesthrough the cam slots 11190 toward the proximal ends 11192, themechanical advantage applied to the closure pin 11210 by the first drivesurfaces 11193 can increase. When the closure pin 11210 enters into theproximal ends 11192, the mechanical advantage applied by the first drivesurfaces 11193 can be at its greatest, and certainly larger than themechanical advantage applied by the first drive surfaces 11193 when theclosure pin 11210 is in the distal ends 11191 of the cam slots 11190.That said, where the distal ends 11191 may apply a lower mechanicaladvantage to the closure pin 11210, the distal ends 11191 may quicklydisplace the closure pin 11210 relative to the cartridge 11080. As theclosure channel 11180 is advanced distally and the mechanical advantageapplied to the closure pin 11210 increases, as discussed above, thefirst drive surfaces 11193 may move the anvil 11090 more slowly for agiven speed of the closure channel 11180.

As illustrated in FIG. 96 , the cartridge channel 11070 can furtherinclude distal closure slots 11215 defined therein which can beconfigured to receive the distal closure pin 11210 as the anvil 11090approaches its closed position. Distal closure slots 11215 aresubstantially vertical and can include open ends at the top of thecartridge channel 11070 and closed ends at the opposite ends thereof.The slots 11215 may be wider at their open ends than their closed ends.In various instances, the closure pin 11210 can contact the closed endsof the closure slots 11215 when the anvil 11090 reaches its closedposition. In such instances, the closed ends of the closure slots 11215can stop the movement of the anvil 11090. In certain instances, theanvil 11090 can contact the staple cartridge 11080 when the anvil 11090is in its closed position. In at least one instance, the anvil 11090 canbe rotated about the pivot pin 11200 until a distal end 11091 of theanvil 11090 contacts a distal end 11081 of the staple cartridge 11080.As illustrated in FIG. 98 , the distal closure pin 11210 which moves theanvil 11090 is positioned distally with respect to the pivot pin 11220.Thus, the closure force applied to the anvil 11090 by the closure driveis applied distally with respect to the pivot which rotatably connectsthe anvil 11090 to the cartridge channel 11070. Similarly, the openingforce applied to the anvil 11090 by the closure drive is applieddistally with respect to the pivot which rotatably connects the anvil11090 to the cartridge channel 11070.

As discussed above, the handle 11015 can include a closure button 11065configured to operate the closure system of the surgical instrument11010. The movement of the closure button 11065 can be detected by asensor or a switch, for example. When the closure button 11065 ispressed, a closure switch 11285 can be activated, or closed, whichcauses power to flow to the closure motor 11110. In such instances, theswitch 11285 can close a power circuit which can supply electrical powerto the closure motor 11110. In certain instances, the surgicalinstrument 11010 can include a microprocessor, for example. In suchinstances, the closure switch 11285 can be in signal communication withthe microprocessor and, when the closure switch 11285 has been closed,the microprocessor can operably connect a power supply to the closuremotor 11110. In any event, a first voltage polarity can be applied tothe closure motor 11110 to rotate the closure output shaft 11130 in afirst direction and close the anvil 11090 and, in addition, a second, oropposite, voltage polarity can be applied to closure motor 11110 torotate the closure output shaft 11130 in a second, or opposite,direction and open the anvil 11090.

In various instances, the surgical instrument 11010 may be configuredsuch that the operator of the surgical instrument 11010 is required tohold the closure button 11065 in a depressed state until the closuredrive has reached its fully closed configuration. In the event that theclosure button 11065 is released, the microprocessor can stop theclosure motor 11110. Alternatively, the microprocessor can reverse thedirection of the closure motor 11110 if the closure button 11065 isreleased prior to the closure drive reaching its fully closedconfiguration. After the closure drive has reached its fully closedconfiguration, the microprocessor may stop the closure motor 11110. Invarious instances, as described in greater detail below, the surgicalinstrument 11010 can comprise a closure sensor 11300 (FIGS. 96 and 98 )configured to detect when the closure system has reached its fullyclosed configuration. The closure sensor 11300 can be in signalcommunication with the microprocessor which can disconnect the powersupply from the closure motor 11110 when the microprocessor receives asignal from the closure sensor 11300 that the anvil 11090 has beenclosed. In various instances, re-pressing the closure button 11065 afterthe closure system has been placed in its closed configuration, butbefore the firing system has been operated, can cause the microprocessorto reverse the direction of the closure motor 11110 and re-open theanvil 11090. In certain instances, the microprocessor can re-open theanvil 11090 to its fully open position while, in other instances, themicroprocessor can re-open the anvil 11090 to a partially open position.

Once the anvil 11090 has been sufficiently closed, the firing system ofthe surgical instrument 11010 can be operated. Referring primarily toFIGS. 95 and 97 , the firing system can include a firing motor 11120.The firing motor 11120 can be positioned adjacent to the closure motor11110. The closure motor 11110 can extend along a first longitudinalmotor axis and the firing motor 11120 can extend along a secondlongitudinal motor axis which is parallel, or at least substantiallyparallel to the first motor axis. The first longitudinal motor axis andthe second longitudinal motor axis can be parallel to the longitudinalaxis 11030 of the surgical instrument 11010. The closure motor 11110 canbe positioned on a first side of the longitudinal axis 11030 and thefiring motor 11120 can be positioned on a second side of thelongitudinal axis 11030. In such instances, the first longitudinal motoraxis can extend along a first side of the longitudinal axis 11030 andthe second longitudinal motor axis can extend along a second side of thelongitudinal axis 11030. In various instances, the first longitudinalmotor axis can extend through the center of the closure shaft 11130.Similar to the above, the firing motor 11120 can include a rotatablefiring shaft 11230 extending therefrom. Also similar to the above, thesecond longitudinal motor axis can extend through the center of thefiring shaft 11230.

Further to the above, a first firing gear 11240 can be mounted to thefiring shaft 11230. The first firing gear 11240 is meshingly engagedwith a firing lead screw drive gear 11250 which is mounted to a firinglead screw 11260. When the firing shaft 11230 is rotated by the motor11120, the firing shaft 11230 can rotate the first firing gear 11240,the first firing gear 11240 can rotate the firing lead screw drive gear11250, and the firing lead screw drive gear 11250 can rotate the firinglead screw 11260. Referring primarily to FIG. 97 , the firing shaft11230, the first firing gear 11240, the firing lead screw drive gear11250, and/or the firing lead screw 11260 can be rotatably supported bythe motor block 11125. The first firing gear 11240 and the firing leadscrew drive gear 11250 can be positioned intermediate the motor block11125 and a first block plate 11126. The first block plate 11126 can bemounted to the motor block 11125 and can also rotatably support thefiring shaft 11230, the first firing gear 11240, the firing lead screwdrive gear 11250, and/or the firing lead screw 11260. In variousinstances, the surgical instrument 11010 can further comprise a secondblock plate 11127 which can be mounted to the first block plate 11126.Similar to the above, the first closure gear 11140, the idler gear11150, and the closure lead screw drive gear 11160 can be positionedintermediate the first block plate 11126 and the second block plate11127. In various instances, the first block plate 11126 and/or thesecond block plate 11127 can rotatably support the closure shaft 11130,the first closure gear 11140, the idler gear 11150, the closure leadscrew drive gear 11160, and/or the closure lead screw 11170.

The motor and gear arrangement described above can aid in conservingspace within the handle 11015 of surgical instrument 11010. As describedabove, and referring primarily to FIG. 97 , the closure motor 11110 andthe firing motor 11120 are located on the motor block 11125. The closuremotor 11110 is located on one side and slightly proximally of the firingmotor 11120. Offsetting one motor proximally from another creates spacefor two gear trains with one gear train behind the other. For example,the closure gear train comprising the first closure gear 11140, theclosure idler gear 11150, and the closure lead screw drive gear 11160 isproximal to the firing gear train comprising the first firing gear 11240and the firing lead screw drive gear 11250. Having motor shafts extendproximally away from the jaws, with the main body of the motor extendingdistally toward the jaws, creates room in the handle 11015 and allows ashorter handle 11015 by having the main body of the motors 11110 and11120 aligned parallel alongside other parts within the handle 11015.

Further to the above, the closure and firing gear trains are designedfor space conservation. In the embodiment depicted in FIG. 97 , theclosure motor 11110 drives three gears, while the firing motor 11120drives two gears; however, the closure gear train and the firing geartrain can include any suitable number of gears. The addition of a thirdgear, i.e., the closure idler gear 11150, to the closure gear trainpermits the closure lead screw 11170 to be shifted downwardly withrespect to the firing lead screw 11260 so that the separate lead screwscan rotate about different axes. Moreover, the third gear eliminates theneed for larger diameter gears to shift the axes of the lead screws sothat the overall diameter of the space required by the gear trains, andthe volume of the handle 11015, can be reduced.

Referring primarily to FIG. 98 , the closure lead screw 11170 can extendalong a first longitudinal shaft axis and the firing lead screw 11260can extend along a second longitudinal shaft axis. The firstlongitudinal shaft axis and the second longitudinal shaft axis can beparallel to the longitudinal axis 11030 of the surgical instrument11010. The first longitudinal shaft axis or the second longitudinalshaft axis can be collinear with the longitudinal axis 11030. In variousinstances, the firing lead screw 11260 can extend along the longitudinalaxis 11030 and the second longitudinal shaft axis can be collinear withthe longitudinal axis 11030. In such instances, the closing lead screw11170 and the first longitudinal shaft axis can be offset with respectto the longitudinal axis 11030.

Further to the above, the firing lead screw 11260 can include a firstend rotatably supported by the motor block 11125, for example, a secondend rotatably supported by the handle 11015, and a threaded portionextending between the first end and the second end. The firing leadscrew 11260 can reside within the “U” shape of the cartridge channel11070 and above the closure lead screw 11170. Referring primarily toFIG. 95 , the firing drive can further comprise a firing block 11265which can include a threaded aperture 11266 threadably engaged with thethreaded portion of the firing lead screw 11260. The firing block 11265can be constrained from rotating with the firing lead screw 11260 suchthat the rotation of the firing lead screw 11260 can translate thefiring block 11265 proximally or distally depending on the directionthat the firing lead screw 11260 is rotated by the firing motor 11120.For instance, when the firing lead screw 11260 is rotated in a firstdirection, the firing lead screw 11260 can displace the firing block11265 distally and, when the firing lead screw 11260 is rotated in asecond direction, the firing lead screw 11260 can displace the firingblock 11265 proximally. As described in greater detail below, the firingblock 11265 can be advanced distally to deploy staples removably storedin the staple cartridge 11080 and/or incise tissue captured between thestaple cartridge 11080 and the anvil 11090.

Further to the above, the firing block 11265 can be affixed to a pusherblock 11270 such that the pusher block 11270 translates with the firingblock 11265. The firing system can further include firing wedges 11280which are attached to and extend distally from the pusher block 11270.The firing wedges 11280 can each include at least one cam surface at adistal end thereof which can be configured to eject staples from thestaple cartridge 11080. The firing system can further comprise a knifeblock 11281 slidably disposed along the firing wedges 11280. In variousinstances, the initial distal movement of the firing block 11265 may notbe transferred to the knife block 11281; however, as the firing block11265 is advanced distally, the pusher block 11270, for example, cancontact the knife block 11281 and push the knife block 11281 and a knife11282 mounted thereto distally. In other instances, the knife block11281 can be mounted to the firing wedges 11280 such that the knifeblock 11281 and the knife 11282 move with the firing wedges 11280throughout the movement of the firing wedges 11280. The firing block11265, the pusher block 11270, the firing wedges 11280, the knife block11281, and the knife 11282 can form a pusher block and knife assembly.In any event, the firing wedges 11280 and the knife 11282 can be moveddistally to simultaneously fire the staples stored within the staplecartridge 11080 and incise the tissue captured between the staplecartridge 11080 and the anvil 11090. The cam surfaces of the firingwedges 11280 can be positioned distally with respect to the cuttingsurface of the knife 11282 such that the tissue captured between thestaple cartridge 11080 and the anvil 11090 can be stapled before it'sincised.

As discussed above, the closure button 11065, when pushed, contacts theclosure switch 11285 to energize closure motor 11110. Similarly, thefiring button 11055, when pushed, contacts a firing switch 11290 toenergize the firing motor 11120. In various instances, the firing switch11290 can close a power circuit which can supply electrical power to thefiring motor 11120. In certain instances, the firing switch 11290 can bein signal communication with the microprocessor of the surgicalinstrument 11010 and, when the firing switch 11290 has been closed, themicroprocessor can operably connect a power supply to the firing motor11120. In either event, a first voltage polarity can be applied to thefiring motor 11120 to rotate the firing output shaft 11230 in a firstdirection and advance the firing assembly distally and a second, oropposite, voltage polarity can be applied to firing motor 11120 torotate the firing output shaft 11230 in a second, or opposite, directionand retract the firing assembly. In various instances, the firing button11055 can include a bi-directional switch configured to operate thefiring motor 11120 in its first direction when the firing button 11055is pushed in a first direction and in its second direction when thefiring button 11055 is pushed in a second direction.

As discussed above, the firing system can be actuated after the closuresystem has sufficiently closed the anvil 11090. In various instances,the anvil 11090 may be sufficiently closed when it has reached its fullyclosed position. The surgical instrument 11010 can be configured todetect when the anvil 11090 has reached its fully closed position.Referring primarily to FIG. 98 , the surgical instrument 11010 caninclude a closure sensor 11300 configured to detect when the closurechannel 11180 has reached the end of its closure stroke and, thus,detect when the anvil 11090 is in its closed position. The closuresensor 11300 can be positioned at or adjacent to the distal end of theclosure lead screw 11170. In at least one instance, the closure sensor11300 can comprise a proximity sensor configured to sense when theclosure channel 11180 is adjacent to and/or in contact with the closuresensor 11300. Similar to the above, the closure sensor 11300 can be insignal communication with the microprocessor of the surgical instrument11010. When the microprocessor receives a signal from the closure sensor11300 that the closure channel 11180 has reached its fully advancedposition and the anvil 11090 is in a closed position, the microprocessorcan permit the firing system to be actuated. Moreover, themicroprocessor can prevent the firing system from being actuated untilthe microprocessor receives such a signal from the closure sensor 11300.In such instances, the microprocessor can selectively apply power from apower source to the firing motor 11120, or selectively control the powerbeing applied to the firing motor 11120, based on the input from theclosure sensor 11300. Ultimately, in these embodiments, the firingswitch 11290 cannot initiate the firing stroke until the instrument isclosed.

Certain embodiments are envisioned in which the firing system of thesurgical instrument 11010 can be operated even though the closure systemis in a partially closed configuration and the anvil 11090 is in apartial closed position. In at least one embodiment, the firing assemblyof the surgical instrument 11010 can be configured to contact the anvil11090 and move the anvil 11090 into its fully closed position as thefiring assembly is advanced distally to fire the staples stored in thestaple cartridge 11080. For instance, the knife 11282 can include acamming member configured to engage the anvil 11090 as the knife 11282is advanced distally which can move the anvil 11090 into its fullyclosed position. The knife 11282 can also include a second cammingmember configured to engage the cartridge channel 11070. The cammingmembers can be configured to position the anvil 11090 relative to thestaple cartridge 11080 and set a tissue gap distance therebetween. In atleast one instance, the knife 11282 can comprise an I-beam which isdisplaced distally to set the tissue gap, eject the staples from thestaple cartridge 11080, and incise the tissue.

The surgical instrument 11010 can a sensor configured to detect when thefiring system has completed its firing stroke. In at least one instance,the surgical instrument 11010 can include a sensor, such as an encoder,for example, which can be configured to detect and count the rotationsof the firing lead screw 11260. Such a sensor can be in signalcommunication with the microprocessor of the surgical instrument 11010.The microprocessor can be configured to count the rotations of thefiring lead screw 11260 and, after the firing lead screw 11260 has beenrotated a sufficient number of times to fire all of the staples from thestaple cartridge 11080, the microprocessor can interrupt the powersupplied to the firing motor 11120 to stop the firing lead screw 11260.In certain instances, the microprocessor can reverse the voltagepolarity applied to the firing motor 11120 to automatically retract thefiring assembly once the firing assembly has fired all of the staples.

As discussed above, the surgical instrument 11010 can include a powersupply. The power supply can include a power supply located external tothe handle 11015 and a cable which can extend into the handle 11015, forexample. The power supply can include at least one battery containedwithin handle 11015. A battery can be positioned in the first handleportion 11020 and/or the handle grip 11040. It is envisioned that thebatteries, gears, motors, and rotating shafts may all be combined in oneunit separable from the rest of handle 11015. Such a unit may becleanable and sterilizable.

In various instances, the surgical instrument 11010 can include one ormore indicators configured to indicate the state of the surgicalinstrument 11010. In at least one embodiment, the surgical instrument11010 can include an LED 11100, for example. To communicate the state ofthe surgical instrument to the user, the LED 11100 can glow in differentcolors during different operating states of surgical instrument 11010.For example, the LED 11100 can glow a first color when the surgicalinstrument 11010 is powered and an unspent staple cartridge 11080 is notpositioned in the cartridge channel 11070. The surgical instrument 11010can include one or more sensors which can be configured to detectwhether a staple cartridge 11080 is present in the cartridge channel11070 and whether staples have been ejected from the staple cartridge11080. The LED 11100 can glow a second color when the surgicalinstrument 11010 is powered and an unspent staple cartridge 11080 ispositioned in the cartridge channel 11070. The LED 11010 can glow athird color when the instrument 11010 is powered, an unspent staplecartridge 11080 is loaded into the cartridge channel 11070, and theanvil 11090 is in a closed position. Such a third color can indicatethat the surgical instrument 11010 is ready to fire the staples from thestaple cartridge 11080. The LED 11100 can glow a fourth color after thefiring process has begun. The LED can glow a fifth color after thefiring process has been completed. This is but one exemplary embodiment.Any suitable number of colors could be utilized to indicate any suitablenumber of states of the surgical instrument 11010. While one or moreLEDs may be utilized to communicate the state of the surgicalinstrument, other indicators could be utilized.

In use, a user of the surgical instrument 11010 may first load thesurgical instrument 11010 with a staple cartridge 11080 by placing thestaple cartridge 11080 into the cartridge channel 11070. Loading thecartridge 11080 into the cartridge channel 11070 may cause the LED 11100to change from a first color to a second color. The user may grasp thehandle grip 11040 and use the thumb activated closure switch 11065 toopen the anvil 11090 of the surgical instrument 11010 in order to placethe staple cartridge 11080 within the cartridge channel 11070. The usercould then position the staple cartridge 11080 on one side of the tissueto be stapled and transected and the anvil 11090 on the opposite side ofthe tissue. Holding closure button 11065 with their thumb, the user mayclose surgical instrument 11010. Release of the closure button 11065before the closing stroke is completed can reopen the anvil 11090 andallow the user to reposition the surgical instrument 11010, ifnecessary. The user may enjoy the advantage of being able to use an openlinear cutter with pivotable jaws without the necessity of assemblinglinear cutter portions. The user may further enjoy the advantage of apistol-grip feel.

As the anvil 11090 is being moved into its fully closed position, theclosure channel 11080 can contact the closure sensor 11300, and theclosure sensor 11300 can signal the microprocessor to arm firing switch11290. At such point, the LED 11100 may glow a third color to show aloaded, closed, and ready-to-fire surgical instrument 11010. The usercan then press the firing button 11055 which contacts the firing switch11290 and causes the firing switch 11290 to energize the firing motor11120. Energizing the firing motor 11120 rotates the firing shaft 11230which, in turn, rotates the first firing gear 11240 and the firing leadscrew drive gear 11250. The firing lead screw drive gear 11250 rotatesthe firing lead screw 11260. Threads of the firing lead screw 11260engage and apply a force against internal threads defined in the firingblock 11265 to move the firing block 11265 distally. The firing block11265 moves pusher block 11270 distally, carrying firing wedges 11280distally. The cam surfaces 11305 at the distal end of the firing wedges11280 cam staples stored within the staple cartridge 11080 toward theanvil 11090, and the anvil 11090 can form the staples to fasten thetissue. The pusher block 11270 engages the knife block 11281 to push theknife block 11281 and the knife 11282 distally to transect the stapledtissue. After the firing stroke has been completed, the firing motor11120 can be reversed to return the pusher block 11270, the knife block11281, the firing wedges 11280, and the knife 11282. The surgicalinstrument 11010 can include a button and/or switch which automaticallyinstructs the microprocessor to retract the firing assembly even thoughthe firing stroke has not yet been completed. In some instances, thefiring assembly may not need to be retracted. In any event, the user canopen the surgical instrument 11010 by pressing the closure button 11065.The closure button 11065 can contact the closure switch 11285 andenergize the closure motor 11110. The closure motor 11110 can beoperated in a reverse direction to retract the closure channel 11180proximally to reopen the anvil 11090 of the surgical instrument 11010.The LED 11100 may glow a fourth color designating a fired cartridge, anda complete procedure.

A surgical stapling instrument 12010 is depicted in FIGS. 99-106 . Theinstrument 12010 can include a handle 12015, a closure drive including aclosure latch 12050 configured to compress tissue between a staplecartridge 12080 and an anvil 12090, and a firing drive configured toeject staples from the staple cartridge 12080 and incise the tissue.FIG. 99 depicts the instrument 12010 in an open, unlatched condition.When the instrument 12010 is in its open, unlatched condition, the anvil12090 is pivoted away from the staple cartridge 12080. In variousinstances, the anvil 12090 can be pivoted relative to the staplecartridge 12080 through a wide angle so that the anvil 12090 and thestaple cartridge 12080 may be easily positioned on opposite sides of thetissue. FIG. 100 depicts the instrument 12010 in a closed, unlatchedcondition. When the instrument 12010 is in its closed, unlatchedcondition, the anvil 12090 has been rotated toward the staple cartridge12080 into a closed position opposite the staple cartridge 12080. Invarious instances, the closed position of the anvil 12090 may depend onthe thickness of the tissue positioned intermediate the anvil 12090 andthe staple cartridge 12080. For instance, the anvil 12090 may reach aclosed position which is further away from the staple cartridge 12080when the tissue positioned intermediate the anvil 12090 and the staplecartridge 12080 is thicker as compared to when the tissue is thinner.FIG. 101 depicts the instrument 12010 in a closed, latched condition.When the instrument 12010 is in its closed, latched condition, theclosure latch 12050 has been rotated to engage the anvil 12090 andposition the anvil 12090 relative to the staple cartridge 12080. At suchpoint, as described in greater detail further below, the firing drive ofthe surgical instrument 12010 can be actuated to fire the staples fromthe staple cartridge 12080 and incise the tissue.

Referring primarily to FIG. 106 , the surgical instrument 12010 caninclude a frame 12020 extending from the handle 12015. The frame 12020can include a frame channel 12022 defined therein which can beconfigured to receive and/or support a cartridge channel 12070. Thecartridge channel 12070 can include a proximal end and a distal end. Theproximal end of the cartridge channel 12070 can be connected to theframe 12020. The distal end of the cartridge channel 12070 can beconfigured to removably receive a staple cartridge 12080 therein. Theframe channel 12022 can include pivot apertures 12207 defined inopposite sides thereof. A pivot pin 12205 can be supported within thepivot apertures 12207 and can extend between the sides of the channel12022. The closure latch 12050 can include a latch frame 12051comprising latch bars 12052. The latch bars 12052 can be rotatablymounted to the frame 12020 via the pivot pin 12205 which can extendthrough pivot apertures 12206 defined in the latch bars 12052. Invarious instances, the pivot apertures 12206, 12207 and the pivot pin12205 can define a fixed axis 12208 about which the closure latch 12050can rotate. The closure latch 12050 can further include a latch housing12057 mounted to the latch bars 12052. When the latch housing 12057 ismoved by the user of the surgical instrument 12010, the latch housing12057 can move the latch bars 12052. The operation of the closure latch12050 is described in greater detail further below.

Further to the above, the anvil 12090 can include a proximal end and adistal end. The distal end of the anvil 12090 can include a plurality ofstaple forming pockets which are alignable, or registerable, with staplecavities defined in the staple cartridge 12080 when the anvil 12090 isin its closed position. The proximal end of the anvil 12090 can bepivotably connected to the frame 12020. The anvil 12090 can include apivot aperture 12201 which can be aligned with pivot apertures 12202defined in the cartridge channel 12207 and a pivot aperture 12203defined in the frame 12020. A pivot pin 12200 can extend through thepivot apertures 12201, 12202, and 12203 and can rotatably connect theanvil 12090 to the cartridge channel 12207. In various instances, thepivot apertures 12201, 12202, and 12203 and the pivot pin 12200 candefine a fixed axis about the anvil 12090 can rotate. In certaininstances, the pivot apertures 12201, 12202 and/or 12203 can belongitudinally elongate, for example, such that the pivot pin 12200 canslide within the pivot apertures 12201, 12202 and/or 12203. In suchinstances, the anvil 12090 can rotate about an axis relative to thecartridge channel 12070 and, in addition, translate relative to thecartridge channel 12070. The anvil 12090 can further include an anvilhousing 12097 mounted thereto. When the anvil housing 12097 is moved bythe user of the surgical instrument 12010, the anvil housing 12097 canmove the anvil 12090 such that the anvil 12090 can be rotated between anopen position (FIG. 99 ) and a closed position (FIG. 100 ).

Further to the above, the anvil 12090 can further include a latch pin12210. The anvil 12090 can include latch pin apertures 12211 and theanvil housing 12097 can include latch pin apertures 12212 which areconfigured to receive and support the latch pin 12210. When the anvil12090 has been moved into its closed position, or a position adjacent toits closed position, the latch 12050 can engage the latch pin 12210 andpull the anvil 12090 toward the staple cartridge 12080. In variousinstances, the latch bars 12052 of the latch 12050 can each include alatch arm 12053 configured to engage the latch pin 12210. The latch12050 can be rotated between an unlatched position (FIG. 100 ) in whichthe latch arms 12053 are not engaged with the latch pin 12210 and alatched position (FIG. 101 ). When the latch 12050 is moved between itsunlatched position and its latched position, the latch arms 12053 canengage the latch pin 12210 and move the anvil 12090 toward the staplecartridge 12080. Each latch arm 12053 can include a camming surfaceconfigured to contact the latch pin 12210. The camming surfaces can beconfigured to push and guide the latch pin 12210 toward the staplecartridge 12080. When the latch 12050 has reached its latched position,the latch pin 12210 can be captured within latch slots 12054 defined inthe latch bars 12052. The latch slots 12054 can be at least partiallydefined by the latch arms 12053. The opposite sides of the latch slots12054 can include lift surfaces which can be configured to engage thelatch pin 12210 and lift the anvil 12090 away from the staple cartridge12080 when the latch 12050 is rotated between its latched position andits unlatched position to open the instrument 12010, as discussed ingreater detail further below.

As discussed above, the anvil 12090 can be moved toward the staplecartridge 12080. In various instances, the movement of the anvil 12090toward the staple cartridge 12080 can be stopped when a distal end ofthe anvil 12090 contacts a distal end of the staple cartridge 12080. Incertain instances, the movement of the anvil 12090 can be stopped whenthe latch pin 12210 contacts the cartridge channel 12070. The cartridgechannel 12070 can include slots 12215 defined therein which areconfigured to receive the latch pin 12210. Each slot 12215 can includean upwardly-facing open end through which the latch pin 12210 can enterthe slot 12215 and, in addition, a closed end. In various instances, thelatch pin 12210 can contact the closed ends of the slots 12215 when theanvil 12090 reaches its closed position. In certain instances, the latchpin 12210 may not contact the closed ends of the slots 12215 if thicktissue is positioned between the anvil 12090 and the staple cartridge12080. In at least one instance, the anvil 12090 can further include astop pin 12095. The stop pin 12095 can be mounted to and supported bythe anvil 12090 via pin apertures 12096 defined therein. The stop pin12095 can be configured to contact the cartridge channel 12070 and stopthe movement of the anvil 12090 toward the staple cartridge 12080.Similar to the above, the cartridge channel 12070 can further includestop slots 12075 defined therein which can be configured to receive thestop pin 12095. Each stop slot 12075 can include an upwardly-facing openend through which the stop pin 12095 can enter the stop slot 12275 and,in addition, a closed end. In various instances, the stop pin 12095 cancontact the closed ends of the stop slots 12075 when the anvil 12090reaches its closed position. In certain instances, the stop pin 12095may not contact the closed ends of the stop slots 12075 if thick tissueis positioned between the anvil 12090 and the staple cartridge 12080.

As discussed above, the cartridge channel 12070 can be mounted to theframe 12020. In various instances, the cartridge channel 12070 can berigidly and fixedly mounted to the frame 12020. In such instances, thecartridge channel 12070 may not be movable relative to the frame 12020and/or the handle 12015. In certain instances, the cartridge channel12070 can be pivotably coupled to the frame 12020. In at least one suchinstance, the cartridge channel 12070 can include pivot apertures 12202defined therein which can be configured to receive the pivot pin 12200.In such circumstances, both the anvil 12090 and the cartridge channel12070 may be rotatable relative to the frame 12020 about the pivot pin12200. The latch 12050 can hold the anvil 12090 and the cartridgechannel 12070 in position when the latch 12050 is engaged with the latchpin 12210.

In certain instances, further to the above, the instrument 12010 caninclude one or more sensors configured to detect whether the anvil 12090is in its closed position. In at least one instance, the instrument12010 can include a pressure sensor positioned intermediate the frame12020 and the cartridge channel 12070. The pressure sensor can bemounted to the frame channel 12022 or the bottom of the cartridgechannel 12070, for example. When the pressure sensor is mounted to thebottom of the cartridge channel 12070, the pressure sensor can contactthe frame channel 12022 when the cartridge channel 12070 is moved towardthe frame channel 12022. The cartridge channel 12070 can be moved towardthe frame channel 12022 if the cartridge channel 12070 is rotatablerelative to the frame channel 12022, as discussed above. In addition toor in lieu of the above, the cartridge channel 12070 can be moved towardthe frame channel 12022 if the cartridge channel 12070 flexes toward theframe channel 12022. The cartridge channel 12070 can flex toward theframe channel 12022 when a compressive load is generated between theanvil 12090 and the cartridge channel 12070. A compressive load betweenthe anvil 12090 and the cartridge channel 12070 can be generated whenthe anvil 12090 is moved into its closed position and/or when the anvil12090 is moved toward the cartridge channel 12070 by the latch 12050.When the anvil 12090 is pushed toward the cartridge channel 12070 and/orwhen the latch 12050 is used to pull the anvil 12090 toward thecartridge channel 12070, the cartridge channel 12070 can bear againstthe pivot pin 12205. In various instances, the cartridge channel 12070can include a slot or groove 12209 defined therein which can beconfigured to receive the pivot pin 12205. In any event, the pressuresensor can be configured to detect the pressure or force being appliedto the cartridge channel 12070. The pressure sensor can be in signalcommunication with a microprocessor of the surgical instrument 12010.When the pressure or force detected by the pressure sensor exceeds athreshold value, the microprocessor can permit the firing system of theinstrument 12010 to be operated. Prior to the pressure or forceexceeding the threshold value, the microprocessor can warn the user ofthe surgical instrument 12010 that the anvil 12090 may not be closed, orsufficiently closed, when the user attempts to operate the firingsystem. In addition to or in lieu of such a warning, the microprocessorcan prevent the firing system of the instrument 12010 from beingoperated if the pressure or force detected by the pressure sensor hasnot exceeded the threshold value.

In certain instances, further to the above, the instrument 12010 caninclude one or more sensors configured to detect whether the latch 12050is in its latched position. In at least one instance, the instrument12010 can include a sensor 12025 positioned intermediate the frame 12020and the cartridge channel 12070. The sensor 12025 can be mounted to theframe channel 12022 or the bottom of the cartridge channel 12070, forexample. When the sensor 12025 is mounted to the bottom of the cartridgechannel 12070, the latch 12050 can contact the sensor 12025 when thelatch 12050 is moved from its unlatched position to its latchedposition. The sensor 12025 can be in signal communication with themicroprocessor of the surgical instrument 12010. When the sensor 12025detects that the latch 12050 is in its latched position, themicroprocessor can permit the firing system of the instrument 12010 tobe operated. Prior to the sensor 12025 sensing that the latch 12050 isin its latched position, the microprocessor can warn the user of thesurgical instrument 12010 that the anvil 12090 may not be closed, orsufficiently closed, when the user attempts to operate the firingsystem. In addition to or in lieu of such a warning, the microprocessorcan prevent the firing system of the instrument 12010 from beingoperated if the latch 12050 is not detected in its latched position. Invarious instances, the sensor 12025 can comprise a proximity sensor, forexample. In certain instances, the sensor 12025 can comprise a HallEffect sensor, for example. In at least one such instance, the latch12050 can include at least one magnetic element, such as a permanentmagnet, for example, which can be detected by the Hall Effect sensor. Invarious instances, the sensor 12025 can be held in position by a bracket12026, for example.

Referring primarily to FIG. 105 , the firing system of the surgicalinstrument 12010 can include a firing motor 12120 configured to rotate afiring shaft 12230. The firing motor 12120 can be mounted to a motorframe 12125 within the handle 12015 of the surgical instrument 12010such that the firing shaft 12230 extends distally. The firing system canfurther comprise a gear train including, one, a first firing gear 12240mounted to the closure shaft 12230 and, two, a lead screw gear 12250mounted to a lead screw 12260. The first firing gear 12240 can bemeshingly engaged with the lead screw gear 12250 such that, when thefirst firing fear 12240 is rotated by the firing shaft 12230, the firstfiring gear 12240 can rotate the lead screw gear 12250 and the leadscrew gear 12250 can rotate the lead screw 12260. Referring primarily toFIG. 104 , the lead screw 12260 can comprise a first end 12261 rotatably12250 mounted within an aperture defined in the motor block 12125 and asecond end 12263 rotatably supported within a bearing mounted to abearing portion 12264 of the handle 12015. The lead screw 12260 canfurther include a threaded portion 12262 extending between the first end12261 and the second end 12263. The firing system can further comprise afiring nut 12265 threadably engaged with the threaded portion 12262 ofthe lead screw 12260. The firing nut 12265 can be constrained fromrotating with the lead screw 12260 such that, when the lead screw 12260is rotated in a first direction by the firing motor 12120, the leadscrew 12260 can advance the firing nut 12265 distally and,correspondingly, when the lead screw 12260 is rotated in a second, oropposite, direction by the firing motor 12120, the lead screw 12260 canretract the firing nut 12265 proximally.

Further to the above, the firing nut 12265 can be mounted to a firingblock 12270 which can translate with the firing nut 12265. In variousinstances, the firing nut 12265 and the firing block 12270 can beintegrally formed. Similar to the above, the firing system can furtherinclude firing bars 12280 extending therefrom which translate with thefiring nut 12265 and the firing block 12270. In various instances, thefiring nut 12265, the firing block 12270, and the firing bars 12280 cancomprise a firing assembly that is translated proximally and/or distallyby the lead screw 12160. When the firing assembly is advanced distallyby the lead screw 12260, the firing bars 12280 can enter into the staplecartridge 12080 and eject the staples therefrom. The firing system canfurther comprise a knife block 12281 and a knife bar 12282 mounted toand extending from the knife block 12281. As the firing block 12270 isadvanced distally, the firing bars 12280 can engage the knife block12281 and advance the knife block 12281 and the knife bar 12282distally. In various instances, the firing block 12270 can move relativeto the knife block 12281 during the initial portion of the firing strokeand then move together during the final portion of the firing stroke. Inat least one such instance, the firing bars 12280 can slide throughslots defined in the knife block 12281 until one or more raised surfacesextending from the firing bars 12280 contact the knife block 12281 andpush the knife block 12281 distally with the firing bars 12280. Invarious instances, the firing assembly can further include the knifeblock 12281 and the knife bar 12282 which can move concurrently with thefiring block 12270 and the firing bars 12280. In either event, as theknife bar 12282 is advanced distally, a cutting edge 12283 of the knifebar 12282 can incise tissue captured between the anvil 12090 and thestaple cartridge 12080. The disclosure of U.S. Pat. No. 4,633,874,entitled SURGICAL STAPLING INSTRUMENT WITH JAW LATCHING MECHANISM ANDDISPOSABLE LOADING CARTRIDGE, which issued on Jan. 6, 1987, isincorporated by reference herein in its entirety.

Referring primarily to FIG. 106 , the firing system of the surgicalinstrument 12010 can include a firing button 12055 and a firing switch12290. When the user of the surgical instrument 12010 depresses thefiring button 12055, the firing button 12055 can contact the firingswitch 12290 and close a firing circuit which can operate the firingmotor 12120. When the user of the surgical instrument 12010 releases thefiring button 12055, the firing circuit can be opened and the powersupplied to the firing motor 12120 can be interrupted. The firing button12055 can be pushed once again to operate the firing motor 12120 onceagain. In certain instances, the firing button 12055 can comprise abi-directional switch which, when pushed in a first direction, canoperate the firing motor 12120 in a first direction and, when pushed ina second direction, can operate the firing motor 12120 in a second, oropposite, direction. The firing switch 12090 and/or any suitablearrangement of firing switches can be in signal communication with themicroprocessor of the surgical instrument 12010 which can be configuredto control the power supplied to the firing motor 12120. In certaininstances, further to the above, the microprocessor may ignore signalsfrom the firing button 12055 until the sensor 12025 has detected thatthe latch 12050 has been closed. In any event, the firing button 12055can be pushed in its first direction to advance the firing bars 12280and the knife 12282 distally and its second direction to retract thefiring bars 12280 and the knife 12282 proximally. In certain instances,the surgical instrument 12010 can include a firing button and switchconfigured to operate the firing motor 12120 in its first direction anda retraction button and switch configured to operate the firing motor12120 in its second direction. After the firing bars 12280 and the knife12282 have been retracted, the latch 12050 can be moved from its latchedposition to its unlatched position to disengage the latch arms 12053from the latch pin 12210. Thereafter, the anvil 12090 can be pivotedaway from the staple cartridge 12080 to return the surgical instrument12010 to an open, unlatched condition. Similar to the above, thesurgical instrument 12010 can include one or more indicators, such asLED 12100, for example, configured to indicate the status of thesurgical instrument 12010. The LED 12100 can be in signal communicationwith the microprocessor of the surgical instrument 12010 and can operatein a similar manner to that described in connection with the LED 11100,for example. The LED 12100 can be held in position by a bracket 12101,for example.

In various instances, the instrument 12010 can include a firing lockoutsystem which can block the advancement of the knife 12282 and/or thefiring bars 12280 if the anvil 12090 is not in a closed, or asufficiently closed, position. Referring to FIGS. 104 and 106 , theinstrument 12010 can comprise a biasing member 12400 mounted to thecartridge channel 12070, for example, which can bias the knife 12282into engagement with a lock portion of the handle 12015. When the anvil12090 is rotated into its closed position, the anvil 12090 can push theknife 12282 downwardly away from the lock portion against the biasingforce of the biasing member 12400. At such point, the knife 12282 can beadvanced distally. Similarly, the instrument 12010 can include a biasingmember which can bias the firing bars 12280 into engagement with a lockportion of the handle 12015 wherein the anvil 12090 can disengage thefiring bars 12280 from the lock portion when the anvil 12090 is movedinto its closed position.

The surgical instrument 12010 can comprise a manually driven closuresystem and a motor driven staple firing system. A portion 12040 of thehandle 12015 can be gripped by one hand of the user of the surgicalinstrument 12010 and the anvil 12090 and the latch 12050 can bemanipulated by their other hand. As part of closing the latch 12050, inat least one embodiment, the user can move one of their hands in thegeneral direction of their other hand which can reduce the incidentaland accidental movement of the surgical instrument 12010. The surgicalinstrument 12010 can be powered by any suitable power source. Forinstance, an electrical cable can extend from an external power sourceand into the handle 12015. In certain instances, a battery can be storedin the handle 12015, for example.

A surgical stapling instrument 13010 is illustrated in FIGS. 107-110 .FIG. 107 is a side view of the surgical instrument 13010 illustratedwith some components removed and others shown in cross-section. Theinstrument 13010 can comprise a handle 13015, a first actuator 13020, asecond actuator 13030, a shaft assembly 13040, and an end effector 13012including an anvil 13050 and a staple cartridge 13055. The shaft portion13040 and the anvil 13050 can operate as shown and discussed in U.S.Pat. No. 5,704,534, entitled ARTICULATION ASSEMBLY FOR SURGICALINSTRUMENTS, which issued on Jan. 6, 1998. The disclosure of U.S. Pat.No. 5,704,534, entitled ARTICULATION ASSEMBLY FOR SURGICAL INSTRUMENTS,which issued on Jan. 6, 1998, is incorporated herein by reference by itsentirety. An electrical input cable 13018 can connect the instrument13010 to an external power source. In at least one instance, theexternal power source can comprise a generator, such as the GEN11generator manufactured by Ethicon Energy, Cincinnati, Ohio, for example.In various instances, the external power source can comprise an AC to DCadaptor. In certain instances, the instrument 13010 can be powered by aninternal battery, such as the batteries shown and discussed in U.S. Pat.No. 8,210,411, entitled MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT, whichissued on Jul. 3, 2012, for example. The disclosure of U.S. Pat. No.8,210,411, entitled MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT, whichissued on Jul. 3, 2012, is incorporated herein by reference in itsentirety.

In various instances, referring primarily to FIG. 107 , the anvil 13050of the end effector 13012 can be movable between an open position, asillustrated in FIG. 107 , and a closed position in which the anvil 13050is positioned adjacent to, or in contact with, the staple cartridge13055, as described in greater detail further below. In at least onesuch instance, the staple cartridge 13055 may not be pivotable relativeto the anvil 13050. In certain instances, although not illustrated, thestaple cartridge 13055 can be pivotable relative to the anvil 13050. Inat least one such instance, the anvil 13050 may not be pivotablerelative to the staple cartridge 13055. In any event, the user of theinstrument 13010 can manipulate the end effector 13012 in order toposition tissue T between the anvil 13050 and the cartridge 13055. Oncethe tissue T has been suitably positioned between the anvil 13050 andthe staple cartridge 13055, the user can then pull the first actuator13020 to actuate the closure system of the instrument 13010. The closuresystem can move the anvil 13050 relative to the staple cartridge 13055.For example, the first actuator 13020 can be pulled toward a pistol gripportion 13016 of the handle 13015 to close the anvil 13050, as describedin greater detail further below.

The closure drive can include a closure motor 13105 (FIG. 110 )configured to move the anvil 13050. The closure motor 13105 can bemounted to the handle 13015 via a motor bracket 13101, for example.Squeezing the first actuator 13020 from its open position (FIG. 108 ) toits closed position (FIG. 109 ) can energize the closure motor 13105.Referring primarily to FIG. 110 , the closure motor 13105 can include arotatable output shaft which is operably engaged with a closure leadscrew 13110. When the closure motor 13105 rotates the output shaft in afirst direction, the output shaft can rotate the closure lead screw13110 in the first direction. The closure lead screw 13110 can berotatably supported within the handle 13015 and can include a threadedportion. The closure drive can further comprise a closure nut threadablyengaged with the threaded portion of the closure lead screw 13110. Theclosure nut can be constrained from rotating with the closure lead screw13110 such that the rotational motion of the closure lead screw 13110can translate the closure nut. The closure nut can be engaged with orintegrally formed with a closure yoke 13120. When the closure motor13015 is rotated in its first direction, the closure lead screw 13110can advance the closure yoke 13120 distally. In various instances, theclosure yoke 13120 can be slidably supported within the handle 13015 byrails 13122 extending from the handle 13015 which can constrain themovement of the closure yoke 13120 to a path defined along alongitudinal axis. Such an axis can be parallel to, substantiallyparallel to, collinear with, or substantially collinear with alongitudinal axis defined by the shaft assembly 13040. The closure drivecan further comprise a closure tube 13125 extending distally from theclosure yoke 13120. The closure tube 13125 can also be part of the shaftassembly 13040 and can translate relative to a frame of the shaftassembly 13040. When the closure yoke 13120 is advanced distally by theclosure lead screw 13110, the closure yoke 13120 can advance the closuretube 13125 distally. A distal end of the closure tube 13125 can beoperably engaged with the anvil 13050 such that, when the closure tube13125 is advanced distally, the closure tube 13125 can push the anvil13050 from its open position toward its closed position. U.S. Pat. No.5,704,534, entitled ARTICULATION ASSEMBLY FOR SURGICAL INSTRUMENTS,which issued on Jan. 6, 1998, discloses a manually-driven closuresystem.

In at least one form, the instrument 13010 can include a closure systemswitch positioned in the handle 13015 which can be closed when the firstactuator 13020 is moved from its open position (FIG. 108 ) toward itsclosed position (FIG. 109 ). In certain instances, the closure systemswitch can be closed when the first actuator 13020 is in its closedposition (FIG. 109 ). In either event, when the closure system switch isclosed, a closure system power circuit can be closed to supplyelectrical power to the closure motor 13105 in order to rotate theclosure motor 13105 in its first direction, as discussed above. Incertain instances, the surgical instrument 13010 can include amicroprocessor and, similar to the above, the closure system switch canbe in signal communication with the microprocessor. When the closuresystem switch sends a signal to the microprocessor indicating that thefirst actuator 13020 has been closed, the microprocessor can permitpower to be supplied the closure motor 13105 to operate the closuremotor 13105 in its first direction and move the anvil 13050 toward itsclosed position. In various instances, the closure motor 13105 can movethe anvil 13050 toward its closed position so long as the first actuator13020 is at least partially actuated and the closure system switch is ina closed state. In the event that the user releases the first actuator13020 and the first actuator 13020 is returned to its unactuatedposition, the closure system switch can be opened and the power suppliedto the closure motor 13105 can be interrupted. Such instances may leavethe anvil 13050 in a partially closed position. When the first actuator13020 is actuated once again and the closure system switch has beenclosed, power can be supplied to the closure motor 13105 once again tomove the anvil 13050 toward its closed position. In view of the above,the user of the surgical instrument 13010 can actuate the first actuator13020 and wait for the closure motor 13105 to position the anvil 13050in its fully closed position.

In at least one form, the movement of the first actuator 13020 can beproportional to the movement of the anvil 13050. The first actuator13020 can move through a first, or actuator, range of motion when it ismoved between its open position (FIG. 108 ) and its closed position(FIG. 109 ). Similarly, the anvil 13050 can move through a second, oranvil, range of motion when it is moved between its open position (FIG.107 ) and its closed position. The actuator range of motion cancorrespond to the anvil range of motion. By way of example, the actuatorrange of motion can be equal to the anvil range of motion. For instance,the actuator range of motion can comprise about 30 degrees and the anvilrange of motion can comprise about 30 degrees. In such instances, theanvil 13050 can be in its fully open position when the first actuator13020 is in its fully open position, the anvil 13050 can be rotated 10degrees toward its closed position when the first actuator 13020 isrotated 10 degrees toward its closed position, the anvil 13050 can berotated 20 degrees toward its closed position when the first actuator13020 is rotated 20 degrees toward its closed position, and so forth.This directly proportional movement between the first actuator 13020 andthe anvil 13050 can give the user of the instrument 13010 a sense of theanvil position 13050 relative to the staple cartridge 13055 in the eventthat the anvil 13050 is obstructed from view in the surgical site.

Further to the above, the anvil 13050 can be responsive to both closingand opening motions of the first actuator 13020. For example, when thefirst actuator 13020 is moved 10 degrees toward the pistol grip 13016,the anvil 13050 can be moved 10 degrees toward the staple cartridge13055 and, when the first actuator 13020 is moved 10 degrees away fromthe pistol grip 13016, the anvil 13050 can be moved 10 degrees away fromthe staple cartridge 13055. While the movement of the first actuator13020 and the movement of the anvil 13050 can be directly proportionalaccording to a 1:1 ratio, other ratios are possible. For instance, themovement of the first actuator 13020 and the movement of the anvil 13050can be directly proportional according to a 2:1 ratio, for example. Insuch instances, the anvil 13050 will move 1 degree relative to thestaple cartridge 13055 when the first actuator 13020 is moved 2 degreesrelative to the pistol grip 13016. Moreover, in such instances, therange of motion of the first actuator 13020 may be twice the range ofmotion of the anvil 13050. In another instance, the movement of thefirst actuator 13020 and the movement of the anvil 13050 can be directlyproportional according to a 1:2 ratio, for example. In such instances,the anvil 13050 will move 2 degrees relative to the staple cartridge13055 when the first actuator 13020 is moved 1 degree relative to thepistol grip 13016. Moreover, in such instances, the range of motion ofthe first actuator 13020 may be half the range of motion of the anvil13050. In various instances, the motion of the first actuator 13020 maybe linearly proportional to the motion of the anvil 13050. In otherinstances, the motion of the first actuator 13020 may be non-linearlyproportional to the motion of the anvil 13050. Regardless of the ratiothat is used, such embodiments can be possible through the use of apotentiometer, for example, which can evaluate the rotation of the firstactuator 13020, as will be discussed in greater detail further below.

Further to the above, referring to FIGS. 108-110 , the closure system ofthe instrument 13010 can comprise a slide potentiometer 13090 which candetect the movement of the first actuator 13020. The first actuator13020 can be pivotably mounted to the handle 13015 via a pivot 13021.The first actuator 13020 can comprise a gear portion 13070 comprising aplurality of gear teeth extending circumferentially about the pivot13021. When the first actuator 13020 is rotated proximally toward thepistol grip 13016, further to the above, the gear portion 13070 can berotated distally. Correspondingly, when the first actuator 13020 isrotated distally away from the pistol grip 13016, the gear portion 13070can be rotated proximally. The closure system can further comprise aclosure yoke rack 13080 which is slidably supported within the handle13015. The closure yoke rack 13080 can comprise a longitudinal array ofteeth extending along a bottom surface thereof which faces the gearportion 13070 of the first actuator 13020. The gear portion 13070 of thefirst actuator 13020 can be meshingly engaged with the array of teethdefined on the closure yoke rack 13080 such that, when the firstactuator 13020 is rotated about the pivot 13021, the first actuator13020 can displace the closure yoke rack 13080 proximally or distally,depending on the direction in which the first actuator 13020 is rotated.For instance, when the first actuator 13020 is rotated toward the pistolgrip 13016, the first actuator 13020 can displace the closure yoke rack13080 distally. Correspondingly, when the first actuator 13020 isrotated away from the pistol grip 13016, the first actuator 13020 candisplace the closure yoke rack 13080 proximally. The handle 13015 caninclude a guide slot defined therein which can be configured to slidablysupport the closure yoke rack 13080 and constrain the movement of theclosure yoke rack 13080 to a path defined along a longitudinal axis.This longitudinal axis can be parallel to, substantially parallel to,collinear with, or substantially collinear with a longitudinal axis ofthe shaft assembly 13040.

The closure yoke rack 13080 can include a detectable element 13081mounted thereon. The detectable element 13081 can comprise a magneticelement, such as a permanent magnet, for example. The detectable element13081 can be configured to translate within a longitudinal slot 13091defined in the slide potentiometer 13090 when the closure rack 13080 istranslated within the handle 13015. The slide potentiometer 13090 can beconfigured to detect the position of the detectable element 13081 withinthe longitudinal slot 13091 and convey that position to themicroprocessor of the surgical instrument 13010. For example, when thefirst actuator 13020 is in its open, or unactuated, position (FIG. 108), the detectable element 13081 can be positioned at the proximal end ofthe longitudinal slot 13091 and the potentiometer 13090 can transmit asignal to the microprocessor that can indicate to the microprocessorthat the first actuator 13020 is in its open position. With thisinformation, the microprocessor can maintain the anvil 13050 in its openposition. As the first actuator 13020 is rotated toward the pistol grip13016, the detectable element 13081 can slide distally within thelongitudinal slot 13091. The potentiometer 13090 can transmit a signal,or a plurality of signals, to the microprocessor that can indicate theposition of the first actuator 13020. In response to such a signal, or aplurality of signals, the microprocessor can operate the closure motor13105 to move the anvil 13055 to a position which corresponds to theposition of the first actuator 13020. When the first actuator 13020 isin its closed, or fully actuated, position (FIG. 109 ), the detectableelement 13081 can be positioned at the distal end of the longitudinalslot 13091 and the potentiometer 13090 can transmit a signal to themicroprocessor that can indicate to the microprocessor that the firstactuator 13020 is in its closed position. With this information, themicroprocessor can move the anvil 13050 into its closed position.

When the first actuator 13020 is pulled such that it is substantiallyadjacent to the pistol grip 13016 of the handle 13015, as discussedabove, the closure yoke rack 13080 is moved to its most distal position.When the closure yoke rack 13080 is in its most distal position, aclosure release button 13140 can engage the closure yoke rack 13080 toreleasably hold the closure yoke rack 13080 in its distal most positionand, as a result, releasably hold the anvil 13050 in its closedposition. Referring primarily to FIG. 108 , the closure release button13140 can be pivotably mounted to the handle 13015 about a pivot 13141.The closure release button 13140 can include a lock arm 13142 extendingtherefrom. When the first actuator 13120 is in its unactuated positionand the closure yoke rack 13080 is in its proximal-most position, thelock arm 13142 may be positioned above and/or against a top surface ofthe closure yoke rack 13080. In such a position, the closure yoke rack13080 can slide relative to the lock arm 13142. In some circumstances,the lock arm 13142 can be biased against the top surface of the closureyoke rack 13080. As will be described in greater detail further below,the instrument 13010 can further comprise a lock 13290 configured toreleasably hold the first actuator 13020 and the second actuator 13030in the unactuated configuration depicted in FIG. 108 . A spring 13150can be positioned intermediate the lock 13290 and the firing button13140 which can rotatably bias the closure release button 13140 aboutthe pivot 13141 and position the lock arm 13142 against the top surfaceof the closure yoke rack 13080. In various instances, the lock 13290 caninclude a proximal projection 13296 and the closure release button 13140can include a distal projection 13146 which can be configured to holdand align the spring 13150 in position between the lock 13290 and theclosure release button 13140. When the first actuator 13020 is rotatedinto its actuated position, as illustrated in FIG. 109 , the closureyoke rack 13080 can be in its distal-most position and the lock arm13142 can be biased into, or drop into, a notch 13082 defined in theproximal end of the closure yoke rack 13080. Moreover, when the firstactuator 13020 is moved into its closed, or actuated, positionillustrated in FIGS. 109 and 110 , the first actuator 13020 can push thelock 13290 proximally and rotate the lock 13290 about pivot 13214. In atleast one instance, the first actuator 13020 can include an actuatorprojection 13025 extending therefrom configured to engage a distalprojection 13295 extending from the lock 13290. Such movement of thelock 13290 can compress the spring 13150 between the lock 13290 and theclosure release button 13140 and increase the biasing force applied tothe closure release button 13140. Once the lock arm 13142 is engagedwith the notch 13082, the closure yoke rack 13080 may not be movable, orat least substantially movable, in the proximal direction or the distaldirection.

As discussed above, the first actuator 13020 and the second actuator13030 can be releasably held in and/or biased into their unactuatedpositions illustrated in FIG. 108 . The instrument 13010 can include areturn spring 13210 including a first end coupled to the pivot 13214 anda second end coupled to a spring mount 13034 extending from the secondactuator 13030. The second actuator 13030 can be rotatably mounted tothe handle 13015 about the pivot 13021 and the return spring 13210 canapply a biasing force to the second actuator 13030 to rotate the secondactuator 13030 about the pivot 13021. The lock 13290 can stop therotation of the second actuator 13030 about the pivot 13021. Morespecifically, the spring 13150, which acts to bias the closure returnbutton 13140 into engagement with the closure yoke rack 13080, can alsoact to push the lock 13290 distally such that a lock arm 13292 of thelock 13290 is positioned behind a shoulder 13032 defined on the secondactuator 13030 which can limit the rotation of the second actuator 13030and hold the second actuator 13030 in its unactuated position asillustrated in FIG. 108 . Referring primarily to FIG. 110 , the secondactuator 13030 can comprise a shoulder 13031 which can be configured toabut the gear portion 13070 of the first actuator 13020 and bias thefirst actuator 13020 into its unactuated position (FIG. 108 ). When thefirst actuator 13020 is rotated toward its actuated position (FIG. 109), the first actuator 13020 can at least partially rotate the secondactuator 13030 toward the pistol grip 13016 against the biasing forcesupplied by the spring 13210. In fact, the actuation of the firstactuator 13020 can make the second actuator 13030 accessible to the userof the surgical instrument 13010. Prior to the actuation of the firstactuator 13020, the second actuator 13030 may be inaccessible to theuser. In any event, the reader will recall that the actuation of thefirst actuator 13020 pushes the lock 13295 proximally. Such proximalmovement of the lock 13295 can displace the lock 13295 from behind theshoulder 13032 defined on the second actuator 13030.

Once the first actuator 13020 has been moved and locked into its fullyactuated position (FIG. 109 ) and the anvil 13050 has been moved intoits closed position, as discussed above, the instrument 13010 can beused to staple the tissue positioned intermediate the anvil 13050 andthe staple cartridge 13055. In the event that the user is unsatisfiedwith the position of the tissue between the anvil 13050 and the staplecartridge 13055, the user can unlock the anvil 13050 by depressing theclosure release button 13140. When the closure release button 13140 isdepressed, the lock arm 13142 of the closure release button 13140 can bepivoted upwardly out of the notch 13082 which can permit the closureyoke rack 13080 to move proximally. Moreover, the return spring 13210can return the first actuator 13120 and the second actuator 13130 totheir unactuated positions illustrated in FIG. 109 and, owing to themeshed engagement between the gear portion 13070 and the closure yokerack 13080, the return spring 13210 can return the closure yoke rack13080 back into its proximal position. Such movement of the closure yokerack 13080 can be detected by the slide potentiometer 13090 which cantransmit a signal to the microprocessor of the instrument 13010 that thefirst actuator 13020 has been returned to its unactuated position andthat the anvil 13050 should be returned to its open position. Inresponse thereto, the microprocessor can instruct the closure motor13105 to rotate in its second direction to drive the closure nut of theclosing system proximally and retract the closure tube 13125 proximallywhich will return the anvil 13050 back to its open position. The usercan then reposition the anvil 13050 and the staple cartridge 13055 andre-close the anvil 13050 by actuating the first actuator 13020 onceagain. In various instances, the microprocessor of the instrument 13010can be configured to ignore input signals from the second actuator 13030until the potentiometer 13090 detects that the anvil 13050 is in aclosed, or a sufficiently closed, position.

Once the user is satisfied with the position of the anvil 13050 and thestaple cartridge 13055, further to the above, the user can pull thesecond actuator 13030 to a closed, or actuated, position such that it isin close proximity to the first actuator 13020. The actuation of thesecond actuator 13030 can depress or close a firing switch 13180 in thehandle 13015. In various instances, the firing switch 13180 can besupported by a motor mount 13102 which can also be configured to supportthe closure motor 13105 and/or a firing motor 13100. The closure of thefiring switch 13180 can operate the firing motor 13100. In certaininstances, the firing switch 13180 can be in signal communication withthe microprocessor of the surgical instrument 13010. When themicroprocessor receives a signal from the firing switch 13180 that thesecond actuator 13030 has been sufficiently actuated, the microprocessorcan supply power to the firing motor 13100. In various embodiments, theclosure of the firing switch 13180 can connect the firing motor 13100directly to a DC or AC power source to operate the firing motor 13100.In at least one instance, the firing switch 13180 can be arranged suchthat the firing switch 13180 is not closed until the second actuator13030 has reached its fully closed position. Referring primarily to FIG.110 , the rotation of the second actuator 13030 can be stopped in itsfully closed position when it comes into contact with the first actuator13020. In at least one such instance, the first actuator 13020 cancomprise a stop depression 13023 configured to receive a stop projection13033 extending from the second actuator 13030 when the second actuator13030 reaches its closed position.

The firing motor 13100 can include a rotatable output shaft which isoperably engaged with a firing lead screw 13190 of the firing system.When the firing motor 13100 is operated to rotate its output shaft in afirst direction, the output shaft can rotate the firing lead screw 13190in the first direction. When the firing motor 13100 is operated torotate its output shaft in a second, or opposite, direction, the outputshaft can rotate the firing lead screw 13190 in the second direction.The firing system can further comprise a firing nut which is threadablyengaged with a threaded portion of the firing lead screw 13190. Thefiring nut can be constrained from rotating with the firing lead screw13190 such that the rotation of the firing lead screw 13190 cantranslate the firing nut proximally or distally depending on thedirection in which the firing lead screw 13190 is rotated. The firingsystem can further comprise a firing shaft 13220 operatively connectedto the firing nut which can be displaced with the firing nut. The firingsystem can also comprise a knife bar 13200 and staple deploying firingbands which extend distally from the firing shaft 13220. When the firingmotor 13020 is rotated in its first direction, the firing lead screw13190 can displace the firing nut, the firing shaft 13220, the knife bar13200, and the firing bands distally to eject the staples from thestaple cartridge 13055 and incise the tissue positioned intermediate theanvil 13050 and the staple cartridge 13055. Once the knife 13200 and thefiring bands reach their end of travel, the microprocessor can rotatethe firing motor 13100 in its second, or opposite, direction to bringthe knife 13200 and the bands back to their original position. Invarious instances, the instrument 13010 can include an end of travelsensor in signal communication with the microprocessor which can signalto the microprocessor that the firing drive has reached the end of itsfiring stroke and that the firing stroke should be retracted. Such anend of travel sensor can be positioned in the anvil 13050 and/or thestaple cartridge 13055, for example. In certain instances, an encoderoperably coupled to the firing motor 13100 can determine that the firingmotor 13100 has been rotated a sufficient number of rotations for theknife 13200 and firing bands to reach their end of travel and signal tothe microprocessor that the firing system should be retracted.

Once the second actuator 13030 has been actuated, however, theinstrument 13010 is in its firing state and the microprocessor can beconfigured to ignore any inputs from the first actuator 13020 and/or theslide potentiometer 13090 until the firing system has been returned itto its original position. In various instances, the instrument 13010 caninclude an abort button which, when depressed, can signal to themicroprocessor that the firing assembly should be immediately retracted.In at least one such instance, the firing sequence can be halted whenthe closure release button 13140 is depressed. As discussed above,pressing the closure release button 13140 moves the closure yoke rack13080 proximally which, in turn, moves the detectable element 13081proximally. The proximal movement of the detectable element 13081 can bedetected by the slide potentiometer 13090 which can signal to themicroprocessor to reverse the rotation of the firing motor 13100 toretract the firing assembly and/or operate the closure motor 13105 toopen the anvil 13050.

The instrument 13010 can also include one or more indicators, such asLED 13300, for example, which can be configured to indicate theoperating state of the instrument 13010. In various instances, the LED13300 can operate in a manner similar to that of LED 11100, for example.The instrument 13010 also incorporates the ability to articulate the endeffector 13012. This is done through the articulation knob 13240 asdiscussed in U.S. Pat. No. 5,704,534. Manual rotation of the shaftassembly 13040 is also discussed in U.S. Pat. No. 5,704,534.

In a modular concept of the instrument 13010, the shaft assembly 13040and the end effector 13012 could be disposable, and attached to areusable handle 13015. In another embodiment, the anvil 13050 and thestaple cartridge 13055 are disposable and the shaft assembly 13040 andthe handle 13015 are reusable. In various embodiments, the end effector13012, including the anvil 13015, the shaft assembly 13040, and thehandle 13015 may be reusable and the staple cartridge 13055 may bereplaceable.

FIG. 111 is a perspective view of a surgical stapling instrument 14010.The instrument 14010 can comprise an actuator, or handle, 14020, a shaftportion 14030, a tubular cartridge casing 14040, and an anvil 14050. Theinstrument 14010 can further include a closure system configured to movethe anvil 14050 between an open position and a closed position. Theactuator 14020 can comprise a rotating closure knob 14075 which canoperate the closure system as described in greater detail further below.The instrument 14010 can further include a firing system configured toeject staples which are removably stored in the cartridge casing 14040.The actuator 14020 can further comprise a firing activation trigger14070 which can operate the firing system as described in greater detailfurther below. Shaft portion 14030, cartridge casing 14040, and anvil14050 can operate in a manner similar to that shown and discussed inU.S. Pat. No. 5,292,053, entitled SURGICAL ANASTOMOSIS STAPLINGINSTRUMENT, which issued on Mar. 8, 1994. The disclosure of U.S. Pat.No. 5,292,053, entitled SURGICAL ANASTOMOSIS STAPLING INSTRUMENT, whichissued on Mar. 8, 1994, is incorporated herein by reference in itsentirety.

Further to the above, the actuator 14020 can include a transmission14000 and a slider button 14060 configured to operate the transmission14000. The slider button 14060 is movable between a distal position(FIG. 115 ), which is closer to the cartridge casing 14040, and aproximal position (FIG. 114 ), which is further away from the cartridgecasing 14040. When the slider button 14060 is in its proximal position,the actuator 14020 is in a first operating mode, or closure mode, andcan move the anvil 14050 toward and away from the cartridge casing14040. When the slider button 14060 is in its distal position, theactuator 14020 is in a second operating mode, or firing mode, and caneject staples from the cartridge casing 14040 toward the anvil 14050.When the actuator 14020 is in its closure mode, the rotating closureknob 14075 can be rotated about a longitudinal axis extending throughthe actuator 14020 in order to move the anvil 14050 proximally ordistally depending on the direction in which the closure knob 14075 isrotated. When the actuator 14020 is in its firing mode, the firingactivation trigger 14070 can be rotated proximally to eject the staplesfrom the cartridge casing 14040. The closure system and the firingsystem are discussed in greater detail further below.

The actuator 14020 can comprise an electric motor, such as motor 14090(FIGS. 113-115 ), for example, which can operate the closure drive andthe firing drive via the transmission 14000. The motor 14090 can besupported within an actuator housing 14080 of the actuator 14020.Referring primarily to FIG. 113 , the actuator housing 14080 cancomprise two halves, an actuator housing right half 14080 a and anactuator housing left half 14080 b. Actuator housing halves 14080 a and14080 b can be held together by screws, although any suitable fasteningand/or adhesive methods could be used to assemble actuator housing14080. The motor 14090 can be supported between the actuator housinghalves 14080 a and 14080 b and can include a rotatable shaft 14100extending distally therefrom. In certain instances, the actuator 14020can comprise a motor support 14101 positioned in the housing 14080configured to support the housing of the motor 14100 and constrain themotor housing from rotating relative to the actuator housing 14080. Invarious instances, the rotatable shaft 14100 can comprise an extenderportion 14110 affixed thereto. The shaft 14100 and the extender portion14110 can be rotatably coupled such that they rotate together.

Further to the above, referring primarily to FIG. 116 , the extenderportion 14110 can comprise a cylindrical, or an at least substantiallycylindrical, body 14111 and a flat portion 14120 defined in a distal end14113 of the extender portion 14110. The cylindrical body 14111 of theextender portion 14110 can be rotatably supported within the actuatorhousing 14080 by a bearing 14105. The distal end 14113 of the extenderportion 14110 can be positioned within a slider aperture 14114 definedin a slider 14115. The slider 14115, as will be discussed in greaterdetail further below, is part of the transmission 14000 and can beshifted between a proximal position (FIG. 114 ) in which the slider14115 transmits the rotary motion of the motor 14090 to the closuresystem and a distal position (FIG. 115 ) in which the slider 14115transmits the rotary motion of the motor 14090 to the firing system.When the slider 14115 is shifted between its proximal position (FIG. 114) and its distal position (FIG. 115 ), the slider 14115 can sliderelative to the extender portion 14110. The slider aperture 14114defined in the slider 14115 can define a perimeter which matches, or atleast substantially matches, the perimeter of the distal end 14113 ofthe extender portion 14110 such that, one, the extender portion 14110and the slider 14115 are rotationally coupled together and, two, theslider 14115 can translate relative to the extender portion 14110. In atleast one instance, the slider aperture 14114 comprises a cylindricalportion 14116 which matches the cylindrical body 14111 of the extenderportion 14110 and a flat portion 14117 which matches the flat portion14120 defined in the distal end 14113 of the slider 14115.

Further to the above, the slider 14115 can comprise a tubular, or agenerally tubular, structure. The slider 14115 can comprise a distal end14118 and a plurality of outer circumferential splines 14130 extendingaround an outer surface of the distal end 14118 which can be operablyengaged with the firing drive, as illustrated in FIG. 115 . The slider14115 can further comprise a plurality of internal circumferentialsplines 14140 defined in the distal end of the slider aperture 14114which can be operably engaged with the closure drive, as illustrated inFIG. 114 . The slider 14115 can be part of a slider assembly 14150.Referring primarily to FIG. 116 , the slider assembly 14150 can furthercomprise an upper journal bearing 14160, a lower journal bearing 14170,the slider button 14060, and a slider spring 14180. The upper journalbearing 14160 and the lower journal bearing 14170 combine to form ajournal bearing which can, one, support the slider 14115 loosely enoughso that the slider 14115 may rotate within the journal bearing and, two,displace the slider 14115 proximally and distally. Referring primarilyto FIG. 116 , the slider 14115 can comprise a distal flange 14121 and aproximal flange 14122 extending therefrom which can define a recess14123 therebetween which is configured to closely receive the journalbearing. When the slider button 14060 is pushed distally, the journalbearing can bear against the distal flange 14121 to push the slider14115 distally. Correspondingly, when the slider button 14060 is pushedproximally, the journal bearing can bear against the proximal flange14122 to push the slider 14115 proximally.

The slider assembly 14150 can comprise a lock configured to releasablyhold the slider 14115 in position. Referring primarily to FIG. 116 , theslider button 14060 can comprise a flange 14181 that can selectively fitinto a first depression defined at a first, or proximal, end of alongitudinal slot defined in the actuator housing 14080 and a seconddepression defined at a second, or distal, end of the longitudinal slot.When the flange 14181 is engaged with the proximal depression, theflange 14181 can hold the slider assembly 14150 in its proximal positionwhich operably engages the slider 14115 and the closure drive with themotor 14090. When the flange 14181 is engaged with the distaldepression, the flange 14181 can hold the slider assembly 14150 in itsdistal position which operably engages the slider 14115 and the firingdrive with the motor 14090. The upper journal bearing 14160 can includea journal aperture 14161 configured to slidably receive a shaft 14061 ofthe button 14060. The button 14060 can be pushed downwardly within thejournal aperture 14161 to disengage the flange 14181 from the actuatorhousing 14080. Once the flange 14181 has been disengaged from theactuator housing 14080, the button 14060 can be slid within thelongitudinal slot defined in the actuator housing 14080 to move theslider 14115 between its proximal and distal positions. The spring 14180can be configured to bias the flange 14181 toward the actuator housing14080 and, when the user of the surgical instrument 14010 releases thebutton 14060, the spring 14180 can bias the button 14060 upwardly intoengagement with the actuator housing 14080 once again.

When the slider assembly 14150 is in its proximal position, further tothe above, the slider 14115 is engaged with a closing nut 14190 of theclosure drive. The closing nut 14190 comprises an elongate tubularstructure including closing nut external splines 14200 defined at theproximal end thereof. When the slider 14115 is in its proximal position,the internal splines 14140 of the slider 14115 are meshingly engagedwith the external splines 14200 of the closing nut 14190 such that, whenthe slider 14115 is rotated by the motor 14090, the closing nut 14190 isrotated by the slider 14115. The closing nut 14190 can be rotatablysupported within the actuator housing 14080 by one or more bearings,such as bushing 14220, for example, which rotatably supports the distalend of the closing nut 14190. The closing nut bushing 14220 may becomprised of Delrin, Nylon, copper, brass, bronze, and/or carbon, forexample. In certain instances, the closing nut bushing 14220 cancomprise a ball bearing or roller bearing, for example. In variousinstances, the closing nut bushing 14220 may be an integral portion ofthe actuator housing 14080.

The closing nut 14190 can comprise a longitudinal aperture 14191 definedtherein. The closure system can further comprise a closing rod 14230which can be at least partially positioned within the longitudinalaperture 14191. The closing rod 14230 can comprise a thread 14231defined thereon which is threadably engaged with a closing nut thread14210 defined in the longitudinal aperture 14191. The closing rod 14230can be constrained from rotating with the closing nut 14190 such that,when the closing nut 14190 is rotated in a first direction by the motor14090, the closing rod 14230 can be translated proximally by the closingnut 14190. As illustrated in FIG. 115 , the closing rod 14230 can moveproximally within the longitudinal aperture 14191 of the closing nut14190. Similarly, when the closing nut 14190 is rotated in an opposite,or second, direction by the motor 14090, the closing rod 14230 can betranslated distally by the closing nut 14190. As will be described ingreater detail further below, the closing rod 14230 can be operablyengaged with the anvil 14050 such that, when the closing rod 14230 ispulled proximally, the anvil 14050 can be moved toward the cartridgecasing 14040. Correspondingly, when the closing rod 14230 is pusheddistally, the anvil 14050 can be moved away from the cartridge casing14040. In various instances, a closure stroke length of the closuresystem can be measured between the open position and the closed positionof the anvil 14050. The closing rod 14230 can be at least as long as theclosure stroke length to accommodate the same.

As discussed above, the button 14060 of the actuator 14020 is movablebetween a proximal position (FIG. 114 ) in which the transmission 14000is engaged with the closure drive and a distal position (FIG. 115 ) inwhich the transmission 14000 is engaged with the firing drive. In thisway, the transmission 14000 can be used to selectively couple theclosure drive and the firing drive with the motor 14090. When the userof the surgical instrument 14010 is satisfied with the position of theanvil 14050 relative to the cartridge casing 14040, the user candisplace the button 14060 distally, as illustrated in FIG. 115 , todisengage the slider 14115 from the closing drive and engage the slider14115 with the firing drive. When the slider 14115 is slid distally, theinternal splines 14140 of the slider 14115 are disengaged from theexternal splines 14200 of the closing nut 14190 such that the subsequentrotation of the slider 14115 is no longer transmitted to the closing nut14190 and the closure system. Concurrent with the disengagement of theslider from the closure system, the slider 14115 can become engaged withthe firing system. Alternatively, the slider 14115 can become disengagedfrom the closure system as the slider 14115 is displaced distally and,owing to additional distal displacement of the slider 14115, the slider14115 can become engaged with the firing system. In such circumstances,the transmission 14000 may not operably engage the closure drive and thefiring drive with the motor 14090 at the same time. In any event, thefiring system can include a firing nut 14260 which can be engaged by theslider 14115 when the slider 14115 is moved distally.

Further to the above, referring primarily to FIG. 116 , the firing nut14260 can include an aperture 14261 defined therein which can beconfigured to receive the distal end 14118 of the slider 14115 thereinwhen the slider 14115 is advanced into its distal position (FIG. 115 ).The firing nut aperture 14261 can include firing nut splines 14270defined around an inner circumference thereof which can intermesh withthe outer circumferential splines 14130 of the slider 14115. When theouter circumferential splines 14130 of the slider 14115 are engaged withthe firing nut splines 14270 of the firing nut 14260, the slider 14115can be rotatably coupled with the firing nut 14260 such that therotation of the slider 14115 is transmitted to the firing nut 14260. Theactuator 14020 can further comprise a firing nut bushing 14275 thatrotatably supports the firing nut 14260. The firing nut bushing 14275may comprise a needle bearing, a Delrin, Nylon, and/or other plasticbushing, a metal bushing, or an integral part of the actuator housing14080, for example. The firing nut 14260 can further comprise internalthreads 14272 defined in a distal interior surface of the firing nutaperture 14261. The firing system can further comprise a firing tube14280 threadably engaged with the internal threads 14272 of the firingnut 14260.

In various instances, further to the above, the firing tube 14280 caninclude a thread 14281 defined on an outer surface thereof which isthreadably engaged with the internal threads 14272. The firing tube14280 can be constrained from rotating with the firing nut 14260 suchthat, when the firing nut 14260 is rotated by the motor 14090 and theslider 14115, the firing nut 14260 can translate the firing tube 14280.For instance, when the firing nut 14260 is rotated in a first direction,the firing tube 14280 can be displaced distally by the firing nut 14260and, when the firing nut 14260 is rotated in a second, or opposite,direction, the firing tube 14280 can be displaced proximally by thefiring nut 14260. At least a portion of the firing tube 14280 can bepositioned within the aperture 14261 defined in the firing nut 14260.When the firing tube 14280 is displaced proximally, the firing tube14280 can move proximally within the aperture 14261. When the firingtube 14280 is displaced distally, the firing tube 14280 can movedistally within the aperture 14261. As will be described in greaterdetail below, the firing tube 14280 can be operably connected with afiring member which can eject the staples from the cartridge housing14040 when the firing tube 14280 is advanced distally. The firing tube14280 can retract the firing member when the firing tube 14280 is movedproximally. The firing tube 14280 can be long enough to accommodate thefiring stroke of the firing member when the firing member is movedbetween an unfired position and a fired position. In various instances,the threaded portion of the firing tube 14280 is shorter than thethreaded portion of the closure rod 14230. In such circumstances, thefiring stroke can be shorter than the closure stroke. In otherinstances, the threaded portion of the firing tube 14280 can be the samelength as the threaded portion of the closure rod 14230. In suchinstances, the firing stroke can be the same length as the closurestroke. In certain instances, the threaded portion of the firing tube14280 is longer than the threaded portion of the closure rod 14230. Insuch circumstances, the firing stroke can be longer than the closurestroke.

Further to the above, the actuator 14020 and the shaft portion 14030 cancomprise an integral system. In various instances, the actuator 14020and the shaft portion 14030 can comprise a unitary assembly. In certaininstances, the actuator 14020 can be disassembled from the shaft portion14030. FIG. 34 is a perspective view of the surgical stapling instrument14010 depicting the actuator 14020 disassembled from the shaft portion14030. The instrument 14010 can comprise one or more locks or latchesconfigured to releasably hold the shaft portion 14030 to the actuator14020. For instance, the actuator 14020 can include latches 14025 onopposite sides thereof which are configured to releasably hold the shaftportion 14030 to the actuator 14020. The latches 14025 can be slidbetween a first position in which they are engaged with the shaftportion 14030 and a second position in which they have been disengagedfrom the shaft portion 14030. As described in greater detail below, theactuator 14020 and the shaft portion 14030 can comprise portions of theclosure system which are operably assembled together when the shaftportion 14030 is assembled to the actuator 14020. Similarly, theactuator 14020 and the shaft portion 14030 can comprise portions of thefiring system which are operably assembled together when the shaftportion 14030 is assembled to the actuator 14020.

Further to the above, referring primarily to FIG. 113 , the closuresystem can further comprise a closing fixture piece 14240 affixed to thedistal end of the closing rod 14230. In various instances, a screw canlock the closing fixture piece 14240 to the closing rod 14230 such thatthe closing fixture piece 14240 is translated distally when the closingrod 14230 is translated distally and, correspondingly, translatedproximally when the closing rod 14230 is translated proximally. Theclosing fixture piece 14240 can comprise one or more lateral extensionsthat can fit into grooves in the actuator housing 14080 to align theclosing fixture piece 14240 and the closing rod 14230. The lateralextensions can also prevent the closing rod 14230 and the closingfixture piece 14240 from rotating when the closing rod 14230 is drivenby the closing nut 14190, as discussed above. The closing fixture piece14240 may comprise a closing drive output of the actuator 14020 and canbe attached to a closure drive input of the shaft portion 14030. Theclosure drive input of the shaft portion 14030 can comprise a secondfixture piece 14250 which can be attached to the closing fixture piece14240 when the shaft portion 14030 is assembled to the actuator 14020.The closing fixture piece 14240 can push the second fixture piece 14250distally when the closing fixture piece 14240 is advanced distally bythe closing rod 14230; correspondingly, the closing fixture piece 14240can pull the second fixture piece 14250 proximally when the closingfixture piece 14240 is retracted proximally by the closing rod 14230.

The closing drive portion of the shaft portion 14030 can furthercomprise one or more tension bands 14252 and 14253 mounted to andextending from the second fixture piece 14250. The tension bands 14252and 14253 can be fastened to the second fixture piece 14250 such thatthe second fixture piece 14250 can push the tension bands 14252, 14253distally when the second fixture piece 14250 is advanced distally by theclosing fixture piece 14240 and, correspondingly, such that the secondfixture piece 14250 can pull the tension bands 14252, 14253 proximallywhen the second fixture piece 14250 is retracted proximally by theclosing fixture piece 14240. In various instances, the shaft portion14030 can be curved and, in at least one instance, can include a curvedshaft housing 14031 extending from a proximal housing mount 14032. Incertain instances, the tension bands 14252 and 14253 can be flexible toaccommodate a curved path of the closing drive portion of the shaftportion 14030. The closing drive portion of the shaft portion 14030 canfurther comprise an attachment portion, or trocar, 14258 attached to thetension bands 14253 and 14253. The trocar 14258 can be fastened to thetension bands 14252, 14253 such that the trocar 14258 is advanced andretracted with the tension bands 14252, 14253. The trocar 14258 cancomprise a distal end which can be releasably engaged with the anvil14050 such that the anvil 14050 is advanced and retracted with thetrocar 14258 when the anvil 14050 is assembled to the trocar 14258. U.S.Pat. No. 5,292,053, referenced above, discusses this in greater detail.

Further to the above, referring primarily to FIG. 113 , the firingsystem can further comprise a firing fixture piece 14290 affixed to adistal end of the firing tube 14280. In various instances, a screw canlock the firing fixture piece 14290 to the firing tube 14280 such thatthe firing fixture piece 14290 is translated distally when the firingtube 14280 is translated distally and, correspondingly, translatedproximally when the firing tube 14280 is translated proximally. Thefiring fixture piece 14290 can comprise one or more lateral extensionsthat can fit into grooves in the actuator housing 14080 to align thefiring fixture piece 14290 and the firing tube 14280. The lateralextensions can also prevent the firing tube 14280 and the firing fixturepiece 14290 from rotating when the firing tube 14280 is driven by thefiring nut 14260, as discussed above. The firing fixture piece 14290 maycomprise a firing drive output of the actuator 14020 and can be attachedto a firing drive input of the shaft portion 14030. The firing driveinput of the shaft portion 14030 can comprise a second fixture piece14300 which can be attached to the firing fixture piece 14290 when theshaft portion 14030 is assembled to the actuator 14020. The firingfixture piece 14290 can mate in a tongue-in-groove manner with thesecondary firing fixture piece 14300. When assembled, the firing fixturepiece 14290 can push the second fixture piece 14300 distally when thefiring fixture piece 14290 is advanced distally by the firing tube14280; correspondingly, the firing fixture piece 14290 can pull thesecond fixture piece 14300 proximally when the firing fixture piece14290 is retracted proximally by the firing tube 14280.

The firing drive can further comprise a staple driver 14310 coupled tothe second fixture piece 14300 such that the staple driver 14310 movesproximally and distally with the second fixture piece 14300. When thestaple driver 14310 is moved distally by the second fixture piece 14300,the staple driver 14310 can eject the staples from the cartridge housing14040. In various instances, the second fixture piece 14300 can advancea knife 14320 distally with the staple driver 14310 to incise tissuecaptured between the anvil 14050 and the cartridge housing 14040. Thesecond fixture piece 14300 can retract the staple driver 14310 and theknife 14320 proximally when the second fixture piece 14300 is retractedproximally by the firing fixture piece 14290.

Further to the above, it can be noted that portions of the closingsystem comprising the closing nut 14190 and the closing rod 14230 andportions of the firing system comprising the firing nut 14260 and thefiring tube 14280 can be concentric and nested. The firing nut 14260 andthe firing tube 14280 may be considered an outer mechanism while theclosing nut 14190 and the closing rod 14230 may be considered an innermechanism. Together with the slider 14115, the closing nut 14190, theclosing rod 14230, the firing nut 14260, and the firing tube 14280 cancomprise the transmission 14000. The concentric and nested arrangementof the transmission 14000 can reduce the space required by the closingand firing systems in order to create a smaller and more easily heldactuator 14020. This arrangement also allows the outer mechanism toserve as support and provide bearing surfaces for moving parts of theinner mechanism. In the embodiment shown, the translation members of theinner mechanism are shown longer than the translation members of theouter mechanism. The closing rod 14230 may be, for example, of the orderof two inches while the firing tube 14280 is of the order of one inch,for example; however, any suitable lengths can be used. Longertranslation members are useful when longer translation distances areneeded. In the embodiment shown, the inner mechanism, or closure drive,can drive a load a longer distance than the outer mechanism, or firingdrive. That said, the firing drive could drive a load a longer distancethan the firing drive.

As discussed above, the actuator 14020 and the shaft portion 14030 aredesigned for easy assembly. The firing fixture piece 14290 comprises asemi-circular lip at the end of a distally extending flange. Thissemi-circular lip fits into a semi-circular groove at a proximal end ofthe second firing fixture piece 14300. Because the fit is about asemicircular surface, it is possible to connect firing fixture piece14290 with the second firing fixture piece 14300 by translating thefiring fixture piece 14290 toward the second firing fixture piece 14300in a direction transverse or orthogonal to a general longitudinal axisof the pieces. Connection of the closure assembly pieces is alsofacilitated generally in the same manner. For instance, the closingfixture piece 14240 can comprise a distally extending flange. At adistal end of this flange is a semi-circular lip extending from asubstantially semi-cylindrical portion of the closing fixture piece14240. A circumferential groove on a proximal portion of the secondfixture piece 14250 receives this semi-circular lip to attach theclosing fixture piece 14240 to the second fixture piece 14250. Becauseof the semi-circular nature of closing fixture piece 14240, the closingfixture piece 14240 and the second fixture piece 14250 may be assembledand disassembled by translation transverse or orthogonal to the generallongitudinal axis of the pieces, thus facilitating quick connection anddisconnection of the shaft portion 14030 and the actuator 14020.

Referring generally to FIG. 113 , the firing trigger 14070 and theclosing knob 14075 are further displayed in exploded view to better seetheir interaction with adjacent parts. The closing knob 14075 isrotatable in a first, or clockwise, direction and a second, orcounterclockwise, direction. When the closing knob 14075 is rotated inthe first direction, the closing knob 14075 can contact and close afirst switch and, when the closing knob 14075 is rotated in the seconddirection, the closing knob 14075 can contact and close a second switch.When the first switch is closed by the closing knob 14075, the motor14090 can be energized and operated in a first direction and, when thesecond switch is closed by the closing knob, the motor 14090 can beenergized and operated in a second direction. When the motor 14090 isoperated in its first direction, the motor 14090 can drive the closingrod 14230 distally to move the anvil 14050 away from the cartridgecasing 14040 and, when the motor 14090 is operated in its seconddirection, the motor 14090 can drive the closing rod 14230 proximally tomove the anvil 14050 toward the cartridge casing 14040. The closing knob14075 can be positionable in a center, or neutral, position in whichneither the first switch nor the second switch are closed and the motor14090 is not responsive to the closing knob 14075. In various instances,the instrument 14010 can comprise at least one spring, such as spring14076, for example, configured to bias the closing knob 14075 into itsneutral position, for example.

Turning now to the firing trigger 14070, the firing trigger 14070 isrotatably pinned to the actuator housing 14080 and is spring-loaded by atorsion spring 14071 that forces the firing trigger 14070 to a positionwhich is rotated away from the actuator housing 14080. A firing switch14305 located near the firing trigger 14070 is in a position to becontacted by the firing trigger 14070 when the firing trigger 14070 isrotated toward the actuator housing 14080 against the biasing force ofthe torsion spring 14071. The firing trigger 14070 can close the firingswitch 14305 when the firing trigger 14070 is actuated. When the firingswitch 14305 is closed, the motor 14090 can be operated in a firstdirection to advance the firing tube 14280 and the staple driver 14310distally. When the firing trigger 14070 is released, the torsion spring14071 can move the firing trigger 14070 back to its unactuated positionand out of contact with the firing switch 14305. At such point, thefiring switch 14305 may be in an open condition and the motor 14090 maynot be responsive to the firing trigger 14070. In various instances, theinstrument 14010 can further comprise a safety latch 14320 rotatablypinned to the actuator housing 14080 which is rotatable between a lockedposition which blocks the firing trigger 14070 from being actuated and asecond position in which the firing trigger 14070 can be actuated toclose the firing switch 14035. In any event, the motor 14090 can beoperated in a second direction to retract the firing tube 14280 and thestaple driver 14310. In certain instances, the motor 14090 can beswitched between the first direction and the second direction when thefiring system has reached the end of its firing stroke. In someinstances, the actuator 14020 can further comprise a reversing buttonand switch which can be operated to operate the motor 14090 in itssecond direction.

In view of the above, a method of using the instrument 14010 is providedbelow, although any suitable method could be used. Moreover, it has beendescribed above that the actuator 14020 is capable of providing twooutputs and the shaft portion 14030 is capable of receiving two inputsto perform two functions. Such functions have been described as closingfunctions and firing functions, but the invention is not so limited. Thefunctions could include any suitable functions, such as an articulationfunction, for example. To use the actuator 14020, in various instances,a user can first assemble the actuator 14020 to the shaft portion 14030by moving the actuator 14020 toward the shaft portion 14030perpendicular to the longitudinal axis of the actuator 14020, as seen inFIG. 112 . The user can align the open side of the proximal end of theshaft portion 14030 toward the open side of the distal portion of theactuator 14020 and assemble the pieces together. Such assembly canconnect the closing and firing fixture pieces as discussed above. Asalso discussed above, the latches 14025 on the actuator 14020 can gripledges on the shaft portion housing 14032 to releasably hold theactuator 14020 and the shaft portion 14030 together. After assemblingthe actuator 14020 and the shaft portion 14030, a user can place theslider assembly 14150 in its first position to use the first desiredfunction of the surgical tool of the attached portion. As discussedabove, the button 14060 can be utilized to position the slider assembly14150 in its first portion.

Referring generally to FIG. 114 , the inner splines 14140 on the slider14115 can engage the external splines 14200 on the closing nut 14190when the slider assembly 14150 is in its first position. The user wouldthen rotate closing knob 14075 to position the anvil 14050 relative tothe cartridge housing 14040. As discussed above, the closing knob 14075can be rotated in its first direction to close the first closure switchand move the anvil 14050 away from the cartridge housing 14040 and itssecond direction to close the second closure switch and move the anvil14050 toward the cartridge housing 14040. In certain instances, theclosure of the first closure switch can close a circuit which operatesthe motor 14090 in its first direction and, correspondingly, the closureof the second closure switch can close a circuit which operates themotor 14090 in its second direction. In certain instances, the firstclosure switch and the second closure switch can be in communicationwith a microprocessor of the surgical instrument 14010 which can controlthe electrical power supplied, including the polarity of the electricalpower supplied, to the motor 14090 based on the input from the firstclosure switch and the second closure switch. As discussed above, themotor 14090 can rotate the rotatable shaft 14100, the extender portion14110, the slider 14115, and owing to the configuration of thetransmission 14000, the closing nut 14190. As discussed above, theclosing nut 14190 is threadably engaged with the closing rod 14230 whichdisplaces the anvil 14050 proximally and distally. Alternatively, theclosing rod 14230 could perform some other function.

When the slider assembly 14150 is in its first, or proximal, position,as illustrated in FIG. 114 , the motor 14090 may be responsive to theclosing knob 14075 and not the firing trigger 14070. In at least oneinstance, the lower journal bearing 14170 of the slider assembly 14150can contact and close a first transmission switch 14340 when the sliderassembly 14150 is in its first position. In various instances, the firsttransmission switch 14340 can be in communication with themicroprocessor of the surgical instrument 14010 which can be configuredto ignore input from the firing switch 14305 when the first transmissionswitch 14340 has been closed. In such circumstances, the user of thesurgical instrument 14010 may depress the firing trigger 14070 and themotor 14090 will not be responsive thereto. Rather, in suchcircumstances, the motor 14090 is responsive to the first and secondclosure switches which are actuated by the closing knob 14075 to movethe anvil 14050. When the slider assembly 14150 is moved toward itssecond, or distal, position, as illustrated in FIG. 115 , the lowerjournal bearing 14170 is disengaged from the first transmission switch14340 and the first transmission switch 14340 will return to an opencondition. When the slider assembly 14150 is moved into its second, ordistal, position, the lower journal bearing 14170 can contact and closea second transmission switch 14350. In various instances, the secondtransmission switch 14350 can be in communication with themicroprocessor of the surgical instrument 14010 which can be configuredto ignore input from the closure knob 14075 when the second transmissionswitch 14350 has been closed. In such circumstances, the user of thesurgical instrument 14010 may rotate the closing knob 14075 and themotor 14090 will not be responsive thereto. Rather, in suchcircumstances, the motor 14090 is responsive to the firing switch 14305which is actuated by the firing trigger 14070.

In order to move the slider assembly 14150 from its first position toits second position, as discussed above, the user can depress the sliderbutton 14060 to release the slider button 14060 from its detent and movethe slider assembly 14150 distally to its second position. In suchcircumstances, the slider 14115 can be disengaged from the closing nut14160 and engaged with the firing nut 14260. More particularly, theinner splines 14140 on the slider 14115 can become disengaged from theexternal splines 14200 on the closing nut 14190 and, furthermore, theouter splines 14130 of the slider 14150 can become engaged with theinner splines 14270 of the firing nut 14260. At such point, the user canrotate the safety latch 14320 to its unlocked position to ready thefiring trigger 14070 for firing. The user can fire the firing system byrotating the firing trigger 14070 counterclockwise as depicted in FIG.115 toward actuator housing 14080. As discussed above, the firingtrigger 14070 can contact a firing switch 14305 which can electricallyenergize the motor 14090. Similar to the first configuration of thetransmission 14000, the motor 14090 can rotate the rotatable shaft14100, the extender portion 14110, and the slider 14115; however, in thesecond configuration of the transmission 14000, the slider 14115 rotatesthe firing nut 14260 to translate the firing tube 14280.

In various instances, power can be supplied to the instrument 14010 byan external power source. In certain instances, one or more batteriespositioned within the actuator 14020 could be utilized. The batteriescould be, for example, lithium rechargeable batteries. In someinstances, the batteries and the motor 14090 could be positioned in asealed, removable housing that is cleanable, sterilizable, and reusable.

After the actuator 14020 has been used during a surgical procedure, theuser may disassemble the actuator 14020 from the shaft portion 14030.The user may depress the latches 14025 to disassemble the actuator 14020from the shaft portion 14030. Thereafter, the actuator 14020 can becleaned, sterilized, and reused or disposed of. Similarly, the shaftportion 14030 can be cleaned, sterilized, and reused or disposed of.When the shaft portion 14030 is reused, staples can be reloaded into thecartridge housing 14040. In certain instances, the cartridge housing14040 can include a replaceable cartridge which can be used to reloadthe staples. In various instances, various portions of the actuator14020 may also be combined in a sealed, compartmentalized module whichcan be easily inserted into and removed from the actuator housing 14080.For example, the motor 14090, the rotatable shaft 14100, the extenderportion 14110, the slider assembly 14150, the closing nut 14190, theclosing rod 14230, the firing nut 14260, and the firing tube 14280 maybe combined into a modular assembly removable from the actuator housing14080. Furthermore, portions of the actuator 14020 may be part ofseparate assemblable modules. For example, electronic portions of theactuator 14020, such as the motor 14090 and a battery, may comprise onemodule, while mechanical assemblies containing rotating and/ortranslating parts may comprise a second module. In such circumstances,the first module may be sterilized by different methods than the secondmodule. Such circumstances can facilitate the use of, for example, gammaradiation for the second module which may be inappropriate forsterilizing the first module.

Various additions to the actuator 14020 are envisioned. For example,microprocessing may be utilized to detect the end-of-stroke positions ofthe closing system and/or the firing system and to signal the motor14090 when to stop the closing stroke and/or the firing stroke.Microprocessing could also be utilized to determine the type of shaftassembly that is attached to the actuator 14020. For instance, theactuator 14020 can include a sensor in signal communication with themicroprocessor in the actuator 14020 that a circular stapler shaftassembly is attached the actuator 14020 or that a linear cutter shaftassembly is attached to the actuator 14020. It is envisioned that theactuator 14020 can power many types of surgical tools requiring at leastone and perhaps two or more longitudinal motion inputs, for example. Invarious instances, the actuator 14020 can power a circular stapler, aliner stapler, a right-angle stapler, scissors, graspers, and/or othertypes of surgical instruments, for example.

Further modifications of the actuator 14020 include utilizing multiplemotors so that the number of functions employable by the actuator 14020can be increased. Certain modifications of the actuator 14020 includeperforming more than two functions with the same motor. For example, athird position of the slider assembly 14150 is envisioned wherein athird function is driven by a third nested mechanism. In some instances,further to the above, the slider assembly 14150 may have a thirdposition which is an idler or neutral position wherein no function isdriven by the motor 14090. Further modifications may include the use ofelectrical and/or magnetic means to translate the slider 14115 from oneposition to another. For example, a solenoid may be used to move theslider 14115 from one position to another. A spring may preload theslider 14115 into a default position, and energizing the solenoid maymove the slider 14115 from the default position to a second position.

A surgical stapling instrument 15010 is illustrated in FIGS. 117 and 118. Similar to the above, the instrument 15010 can comprise a handle, aclosure system configured to move an anvil 15090 between an openposition (FIG. 117 ) and a closed position (FIG. 118 ) relative to astaple cartridge 15080 and, in addition, a firing system configured todeploy staples from the staple cartridge 15080 and incise tissuecaptured between the anvil 15090 and the staple cartridge 15080. Thehousing of the surgical instrument handle has been removed from FIGS.117 and 118 for the purposes of illustrating various componentscontained therein. Also similar to the above, the closure system of theinstrument 15010 can comprise a closing motor 15110, a closing geartrain including closure drive screw gear 15160 operably coupled to theclosing motor 15110, and a closure drive screw 15170 operably coupled tothe closure drive screw gear 15160. In various instances, the closingmotor 15110 can be supported by a motor frame 15125 which can, inaddition, rotatably support the closure drive screw gear 15160 and theclosure drive lead screw 15170. The closure system can further include aclosure button 15065 configured to contact and close a closure switch15285 which, when closed, can operate the closing motor 15110. In someinstances, further to the above, the closure button 15065 can beconfigured to contact a closure switch configured to operate the closuremotor 15110 in a first direction and close the anvil 15090 and anopening switch configured to operate the closure motor 15110 in a seconddirection and open the anvil 15090.

Further to the above, the closure system can further comprise a carriage15180 configured to engage the anvil 15090 and move the anvil 15090between its open position (FIG. 117) and its closed position (FIG. 118). The carriage 15180 can include a threaded nut portion 15175 which isthreadably engaged with a threaded portion of the closure drive leadscrew 15170. The carriage 15180 can be constrained from rotating withthe closure drive lead screw 15170 such that the rotation of the closuredrive lead screw 15170 can translate the carriage 15180 proximally anddistally, depending on the direction in which the closure drive leadscrew 15170 is rotated. When the closure drive lead screw 15170 isrotated in a first direction by the closing motor 15110, the closuredrive lead screw 15170 can displace the carriage 15180 distally to closethe anvil 15090. Correspondingly, when the closure drive lead screw15170 is rotated in a second, or opposite, direction, by the closingmotor 15110, the closure drive lead screw 15170 can displace thecarriage 15180 proximally to open the anvil 15090. The carriage 15180can be at least partially disposed around a cartridge channel 15070 and,in various instances, can be slidably retained to the cartridge channel15070. Referring primarily to FIG. 118 , the cartridge channel 15070 caninclude one or more slots 15195 defined in opposite sides thereof whichare configured to slidably receive one or more projections 15185extending inwardly from the carriage 15080. In other circumstances, thechannel 15070 can comprise the projections 15185 and the carriage 15080can comprise the slots 15195. In either event, the slots 15195 and theprojections 15185 can be configured to constrain the movement of thecarriage 15180 to a longitudinal, or substantially longitudinal, path,for example.

The carriage 15080 is movable from a first, or proximal, position (FIG.117 ) to a second, or distal, position (FIG. 118 ) to close the anvil15090. The carriage 15080 can include a crossbar 15081 which isconfigured to contact and move the anvil 15090 when the carriage 15080is moved relative to the anvil 15090. In various instances, the anvil15090 can be pivotably coupled to the cartridge channel 15070 about apivot 15200 and the anvil 15090 can be rotated about the pivot 15200 bythe carriage crossbar 15081. More specifically, the carriage crossbar15181 can be configured to contact a top, or cam, surface 15092 of theanvil 15090 and slide across the top surface 15092 as the carriage 15080is moved distally to rotate the anvil 15090 toward the cartridge 15080positioned in the cartridge channel 15070. In some instances, the distalend 15091 of the anvil 15090 can contact the distal end 15081 of thecartridge 15080 when the anvil 15090 reaches its fully closed position.The carriage 15180 can be advanced distally until it reaches itsdistal-most position and/or the anvil 15090 is in its fully closedposition, which is illustrated in FIG. 118 . In various circumstances,the carriage 15180 can contact and close an end-of-stroke sensor whenthe carriage 15180 reaches its distal-most position. In certaininstances, the end-of-stroke sensor can be in signal communication witha microprocessor of the surgical instrument 15010. When theend-of-stroke sensor is closed by the carriage 15180, the microprocessorcan interrupt the power supplied to the closing motor 15110 and stop theadvancement of the carriage 15180.

As discussed above, the crossbar 15181 of the carriage 15180 can cam theanvil 15090 toward the staple cartridge 15080 by pushing the cam surface15092 downwardly. The anvil 15090 can further comprise a latch pin 15210extending from the sides thereof which can be received in slots 15215defined in the sides of the cartridge channel 15070 when the anvil 15090is rotated toward the staple cartridge 15080. In various instances, thelatch pin 15210 can contact the closed ends of the slots 15215 when theanvil 15090 reaches its closed position, for example. In some instances,the anvil 15090 may be in a closed position and the latch pin 15210 maynot be in contact with the closed ends of the slots 15215. In certaininstances, the closure system can comprise one or more latches 15190configured to engage the latch pin 15210 and/or move the anvil 15090closer to the staple cartridge 15080. The latches 15190 can be rotatablycoupled to the cartridge channel 15070 by a pivot pin 15191 and can berotated about a pivot axis to engage the latch pin 15210. In someinstances, the latches 15190 can engage the latch pin 15210 and positionthe latch pin 15210 against the closed ends of the slots 15215. Eachlatch 15190 can comprise a latch arm 15192 which can slide over thelatch pin 15210 and push the latch pin 15210 downwardly as the latch15190 is rotated distally into its closed position. Each latch arm 15192can at least partially define a latch slot 15193 which can be configuredto receive the latch pin 15210 as the latches 15190 are moved into theiractuated positions. The latch arms 15192 and the closed ends of theslots 15215 can co-operate to trap and/or hold the latch pin 15210 inposition.

Further to the above, the latches 15190 can be moved between anunlatched position (FIG. 117 ) and a latched position (FIG. 118 ) by thecarriage 15180 when the carriage 15180 is advanced distally. To theextent that the anvil 15090 is not moved into its fully closed positionby the crossbar 15181, the latches 15190 can move the anvil 15090 intoits fully closed position. In various instances, the carriage 15180 caninclude distal cam surfaces 15182 defined thereon which can engage thelatches 15190 when the carriage 15180 is advanced distally. In at leastone such instance, each cam surface 15182 can comprise a sloped orangled surface, for example. When the closure drive lead screw 15170 isrotated in its second direction and the carriage 15180 is retractedproximally by the closure drive lead screw 15170, the latches 15190 canbe returned to their unactuated positions. In various instances, theinstrument 15010 can further comprise one or more biasing springs 15195,for example, which can be configured to rotate the latches 15190proximally when the distal cam surfaces 15182 are retracted away fromthe latches 15190. Each latch 15190 can include an aperture 15194defined therein configured to receive a first end of a spring 15195. Asecond end of each spring 15195 can be engaged with a spring post 15079extending from the cartridge channel 15070. When the latches 15190 arerotated distally from their unlatched positions to the their latchedpositions by the carriage 15180, as discussed above, the springs 15195can be resiliently stretched such that, when the carriage 15180 isretracted, the springs 15195 can elastically return to their originalcondition thereby applying a force to the latches 15090 via theapertures 15194, for example. In any event, when the latches 15190 havebeen returned to their unlatched positions, the anvil 15090 can be movedrelative to the staple cartridge 15080 once again.

As discussed above, the crossbar 15181 of the carriage 15180 can contactthe cam surface 15092 of the anvil 15090 to rotate the anvil 15090toward the staple cartridge 15080. The carriage 15180 can also beconfigured to rotate the anvil 15090 away from the staple cartridge15080. In at least one such instance, the anvil 15090 can comprise asecond cam surface 15093 defined thereon which can be contacted by thecrossbar 15181 of the carriage 15080 as the carriage 15080 is movedproximally by the closure drive lead screw 15170. As the reader willappreciate, the closing cam surface 15092 can be defined on a first sideof the pivot pin 15200 and the opening cam surface 15093 can be definedon a second, or opposite, side of the pivot pin 15200. The opening camsurface 15093 can extend at an angle with respect to the closing camsurface 15092. In various instances, the crossbar 15181 can contact andslide relative to the opening cam surface 15093 as the carriage 15180 isretracted. The opening cam surface 15093 can be configured such that thedegree, or amount, in which the anvil 15090 is opened relative to thestaple cartridge 15080 is dependent upon the distance in which thecrossbar 15181 is retracted proximally. For instance, if the crossbar15181 is retracted a first distance proximal to the pivot 15200, thecrossbar 15181 can pivot the anvil 15090 upwardly away from the staplecartridge 15080 a first degree and, if the crossbar 15181 is retracted asecond distance proximal to the pivot 14200 which is larger than thefirst distance, the crossbar 15181 can pivot the anvil 15090 upwardlyaway from the staple cartridge 15080 a second degree which is largerthan the first degree.

The closing system discussed above can permit the user of the surgicalinstrument to pivot the anvil 15090 between an open and a closedposition without having to manipulate the anvil 15090 by hand. Theclosing system discussed above can also latch or lock the anvil 15090 inits closed position automatically without requiring the use of aseparate actuator. To the extent that the user is unsatisfied with thepositioning of the tissue between the anvil 15090 and the staplecartridge 15080 when the anvil 15090 is in its closed position, the usercan reopen the anvil 15090, reposition the anvil 15090 and the staplecartridge 15080 relative to the tissue, and then close the anvil 15090once again. The user can open and close the anvil 15090 as many times asneeded prior to actuating the firing system of the instrument 15010. Thefiring system can comprise a firing motor 15120 mounted to the motorframe 15125, a firing drive gear train operably coupled to the firingmotor 15120 including a firing gear 15240, a firing lead screw gear15250, and a firing drive lead screw 15260. Similar to the above, thefiring drive gear train and/or the firing drive lead screw 15260 can berotatably supported by the motor frame 15125. The firing drive canfurther comprise a firing trigger 15055 configured to close a firingswitch 15290 when the firing trigger 15055 is depressed to operate thefiring motor 15120. When the firing motor 15120 is operated in a firstdirection to rotate the firing drive lead screw 15260 in a firstdirection, the firing drive can deploy the staples removably stored inthe staple cartridge 15080 and incise the tissue captured between theanvil 15090 and the staple cartridge 15080. When the firing motor 15120is operated in a second direction to rotate the firing drive lead screw15260 in a second, or opposite, direction, the firing drive can beretracted. Thereafter, the anvil 15090 can be reopened to remove thetissue from between the anvil 15090 and the staple cartridge 15080. Insome instances, the firing drive may not need to be retracted to openthe anvil 15090. In such instances, the firing drive may not engage theanvil 15090 as it is advanced distally. In at least one such instance,the firing drive can enter into the staple cartridge 15080 to eject thestaples therefrom and a knife edge may travel between the staplecartridge 15080 and the anvil 15090 to incise the tissue. The firingdrive may not lock the anvil 15090 in its closed position, althoughembodiments are envisioned in which the firing drive could lock theanvil 15090 in its closed position. Such embodiments could utilize anI-beam, for example, which can engage the anvil 15090 and the staplecartridge 15080 and hold them in position relative to each other as theI-beam is advanced distally.

The instrument 15010 can be powered by an external power source and/oran internal power source. A cable can enter into the actuator housing15080 to supply power from an external power source, for example. One ormore batteries, such as battery 15400, for example, can be positionedwithin the handle of the instrument 15010 to supply power from aninternal power source, for example. The instrument 15010 can furthercomprise one or more indicators, such as LED indicator 15100, forexample, which can indicate the operating state of the instrument 15010,for example. The LED indicator 15100 can operate the same manner as or asimilar manner to the LED indicator 11100 described above, for example.The LED indicator 15100 can be in signal communication with themicrocontroller of the instrument 15010 which can be positioned on aprinted circuit board 15500, for example.

Previous surgical instruments have utilized a manually-driven closuresystem configured to move an anvil between an open position and a closedposition. Various embodiments disclosed herein utilize a motor-drivenclosure system configured to move an anvil between an open position anda closed position relative to a fixed staple cartridge. Otherembodiments are envisioned in which an anvil can be fixed and amotor-driven closure system could move a staple cartridge between anopen position and a closed position. In either event, the motor of theclosure system can set the tissue gap between the anvil and the staplecartridge. In various instances, the closure system of the surgicalinstrument is separate and distinct from the firing system. In otherinstances, the closure system and the firing system can be integral.When the closure system and the firing system are separate and distinct,the user of the surgical instrument can evaluate the position of theanvil and the staple cartridge relative to the tissue that is to bestapled and incised before operating the firing system.

As discussed above, an end effector of a surgical instrument, such asend effector 1000, for example, can be configured to clamp tissuebetween an anvil jaw 1040 and a staple cartridge 1060 thereof. When theanvil jaw 1040 is in its closed position, a tissue gap can be definedbetween the anvil jaw 1040 and the staple cartridge 1060. In certaininstances, the end effector 1000 may be suitable for use with thintissue, thick tissue, and tissue having a thickness intermediate thethin tissue and the thick tissue. The thinnest tissue and the thickesttissue in which the end effector 1000 can be suitably used to staple candefine a tissue thickness range for the end effector 1000. In variousinstances, a surgical instrument system can include a handle and aplurality of end effectors which can be assembled to the handle, whereinone or more of the end effectors can have different tissue thicknessranges. For instance, a first end effector can have a first tissuethickness range and a second end effector can have a second tissuethickness range which is different than the first tissue thicknessrange. In some instances, the first tissue thickness range and thesecond tissue thickness range can be discrete while, in other instances,the first tissue thickness range and the second tissue thickness rangecan partially overlap. Surgical instrument systems can utilize anysuitable number of end effectors having different tissue thicknessranges where some of the tissue thickness ranges may at least partiallyoverlap and other tissue thickness ranges may not overlap at all.

In various instances, further to the above, a staple cartridge of an endeffector, such as staple cartridge 1060 of end effector 1000, forexample, can be replaceable. In various instances, the staple cartridge1060 can be removably locked into position within the lower jaw 1020 ofthe end effector 1000. Once locked into position, the deck, or tissuecontacting, surface of the staple cartridge 1060 may not move, or atleast substantially move, relative to the lower jaw 1020. Thus, when theanvil jaw 1040 is moved into its closed position, a fixed distance, ortissue gap, can be defined between the anvil jaw 1040 and the decksurface of the staple cartridge 1060. To change this fixed distance, thestaple cartridge 1060 can be removed from the lower jaw 1020 and adifferent staple cartridge can be removably locked within the lower jaw1020. The deck surface of the different staple cartridge can beconfigured to provide a different tissue gap than the tissue gapprovided by the staple cartridge 1060. Embodiments are envisioned inwhich a surgical instrument system includes a handle, a plurality of endeffectors which can be assembled to the handle, and a plurality ofstaple cartridges which can be replaceably inserted into the endeffectors. Such an embodiment can allow a user to select an end effectorcapable of being used with a range of tissue thicknesses and the staplecartridge selected for use with the end effector can adjust or fine tunethe range of tissue thicknesses that can be stapled by the end effector.In certain instances, a first staple cartridge of the surgicalinstrument system can include a first type of staple and a second staplecartridge can include a second type of staple. For example, the firststaple cartridge can include staples having a first unformed, orunfired, height, and the second staple cartridge can include stapleshaving a second unformed, or unfired, height which is different that thefirst height.

The entire disclosures of:

U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC DEVICE,which issued on Apr. 4, 1995;

U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT HAVINGSEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which issued on Feb. 21,2006;

U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING ANDFASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which issued onSep. 9, 2008;

U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL INSTRUMENTWITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS, which issued on Dec.16, 2008;

U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING ANARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;

U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS, whichissued on Jul. 13, 2010;

U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE IMPLANTABLEFASTENER CARTRIDGE, which issued on Mar. 12, 2013;

U.S. patent application Ser. No. 11/343,803, entitled SURGICALINSTRUMENT HAVING RECORDING CAPABILITIES, filed Jan. 31, 2006, now U.S.Pat. No. 7,845,537;

U.S. patent application Ser. No. 12/031,573, entitled SURGICAL CUTTINGAND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed Feb. 14, 2008;

U.S. patent application Ser. No. 12/031,873, entitled END EFFECTORS FORA SURGICAL CUTTING AND STAPLING INSTRUMENT, filed Feb. 15, 2008, nowU.S. Pat. No. 7,980,443;

U.S. patent application Ser. No. 12/235,782, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT, filed Sep. 23, 2008, now U.S. Pat. No.8,210,411;

U.S. patent application Ser. No. 12/249,117, entitled POWERED SURGICALCUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM,filed Oct. 10, 2008, now U.S. Pat. No. 8,608,045;

U.S. patent application Ser. No. 12/647,100, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROLASSEMBLY, filed Dec. 24, 2009, now U.S. Pat. No. 8,220,688;

U.S. patent application Ser. No. 12/893,461, entitled STAPLE CARTRIDGE,filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;

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U.S. patent application Ser. No. 13/524,049, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15, 2012,now U.S. Pat. No. 9,101,358;

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U.S. patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. PatentApplication Publication No. 2014/0263552;

U.S. Patent Application Publication No. 2007/0175955, entitled SURGICALCUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM,filed Jan. 31, 2006; and

U.S. Patent Application Publication No. 2010/0264194, entitled SURGICALSTAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR, filed Apr. 22,2010, now U.S. Pat. No. 8,308,040, are hereby incorporated by referenceherein.

As described earlier, sensors may be configured to detect and collectdata associated with the surgical device. The processor processes thesensor data received from the sensor(s).

The processor may be configured to execute operating logic. Theprocessor may be any one of a number of single or multi-core processorsknown in the art. The storage may comprise volatile and non-volatilestorage media configured to store persistent and temporal (working) copyof the operating logic.

In various embodiments, the operating logic may be configured to processthe data associated with motion, as described above. In variousembodiments, the operating logic may be configured to perform theinitial processing, and transmit the data to the computer hosting theapplication to determine and generate instructions. For theseembodiments, the operating logic may be further configured to receiveinformation from and provide feedback to a hosting computer. Inalternate embodiments, the operating logic may be configured to assume alarger role in receiving information and determining the feedback. Ineither case, whether determined on its own or responsive to instructionsfrom a hosting computer, the operating logic may be further configuredto control and provide feedback to the user.

In various embodiments, the operating logic may be implemented ininstructions supported by the instruction set architecture (ISA) of theprocessor, or in higher level languages and compiled into the supportedISA. The operating logic may comprise one or more logic units ormodules. The operating logic may be implemented in an object orientedmanner. The operating logic may be configured to be executed in amulti-tasking and/or multi-thread manner. In other embodiments, theoperating logic may be implemented in hardware such as a gate array.

In various embodiments, the communication interface may be configured tofacilitate communication between a peripheral device and the computingsystem. The communication may include transmission of the collectedbiometric data associated with position, posture, and/or movement dataof the user's body part(s) to a hosting computer, and transmission ofdata associated with the tactile feedback from the host computer to theperipheral device. In various embodiments, the communication interfacemay be a wired or a wireless communication interface. An example of awired communication interface may include, but is not limited to, aUniversal Serial Bus (USB) interface. An example of a wirelesscommunication interface may include, but is not limited to, a Bluetoothinterface.

For various embodiments, the processor may be packaged together with theoperating logic. In various embodiments, the processor may be packagedtogether with the operating logic to form a System in Package (SiP). Invarious embodiments, the processor may be integrated on the same diewith the operating logic. In various embodiments, the processor may bepackaged together with the operating logic to form a System on Chip(SoC).

Various embodiments may be described herein in the general context ofcomputer executable instructions, such as software, program modules,and/or engines being executed by a processor. Generally, software,program modules, and/or engines include any software element arranged toperform particular operations or implement particular abstract datatypes. Software, program modules, and/or engines can include routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, program modules, and/or enginescomponents and techniques may be stored on and/or transmitted acrosssome form of computer-readable media. In this regard, computer-readablemedia can be any available medium or media useable to store informationand accessible by a computing device. Some embodiments also may bepracticed in distributed computing environments where operations areperformed by one or more remote processing devices that are linkedthrough a communications network. In a distributed computingenvironment, software, program modules, and/or engines may be located inboth local and remote computer storage media including memory storagedevices. A memory such as a random access memory (RAM) or other dynamicstorage device may be employed for storing information and instructionsto be executed by the processor. The memory also may be used for storingtemporary variables or other intermediate information during executionof instructions to be executed by the processor.

Although some embodiments may be illustrated and described as comprisingfunctional components, software, engines, and/or modules performingvarious operations, it can be appreciated that such components ormodules may be implemented by one or more hardware components, softwarecomponents, and/or combination thereof. The functional components,software, engines, and/or modules may be implemented, for example, bylogic (e.g., instructions, data, and/or code) to be executed by a logicdevice (e.g., processor). Such logic may be stored internally orexternally to a logic device on one or more types of computer-readablestorage media. In other embodiments, the functional components such assoftware, engines, and/or modules may be implemented by hardwareelements that may include processors, microprocessors, circuits, circuitelements (e.g., transistors, resistors, capacitors, inductors, and soforth), integrated circuits, application specific integrated circuits(ASIC), programmable logic devices (PLD), digital signal processors(DSP), field programmable gate array (FPGA), logic gates, registers,semiconductor device, chips, microchips, chip sets, and so forth.

Examples of software, engines, and/or modules may include softwarecomponents, programs, applications, computer programs, applicationprograms, system programs, machine programs, operating system software,middleware, firmware, software modules, routines, subroutines,functions, methods, procedures, software interfaces, application programinterfaces (API), instruction sets, computing code, computer code, codesegments, computer code segments, words, values, symbols, or anycombination thereof. Determining whether an embodiment is implementedusing hardware elements and/or software elements may vary in accordancewith any number of factors, such as desired computational rate, powerlevels, heat tolerances, processing cycle budget, input data rates,output data rates, memory resources, data bus speeds and other design orperformance constraints.

One or more of the modules described herein may comprise one or moreembedded applications implemented as firmware, software, hardware, orany combination thereof. One or more of the modules described herein maycomprise various executable modules such as software, programs, data,drivers, application program interfaces (APIs), and so forth. Thefirmware may be stored in a memory of the controller 2016 and/or thecontroller 2022 which may comprise a nonvolatile memory (NVM), such asin bit-masked read-only memory (ROM) or flash memory. In variousimplementations, storing the firmware in ROM may preserve flash memory.The nonvolatile memory (NVM) may comprise other types of memoryincluding, for example, programmable ROM (PROM), erasable programmableROM (EPROM), electrically erasable programmable ROM (EEPROM), or batterybacked random-access memory (RAM) such as dynamic RAM (DRAM),Double-Data-Rate DRAM (DDRAM), and/or synchronous DRAM (SDRAM).

In some cases, various embodiments may be implemented as an article ofmanufacture. The article of manufacture may include a computer readablestorage medium arranged to store logic, instructions and/or data forperforming various operations of one or more embodiments. In variousembodiments, for example, the article of manufacture may comprise amagnetic disk, optical disk, flash memory or firmware containingcomputer program instructions suitable for execution by a generalpurpose processor or application specific processor. The embodiments,however, are not limited in this context.

The functions of the various functional elements, logical blocks,modules, and circuits elements described in connection with theembodiments disclosed herein may be implemented in the general contextof computer executable instructions, such as software, control modules,logic, and/or logic modules executed by the processing unit. Generally,software, control modules, logic, and/or logic modules comprise anysoftware element arranged to perform particular operations. Software,control modules, logic, and/or logic modules can comprise routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, control modules, logic, and/or logicmodules and techniques may be stored on and/or transmitted across someform of computer-readable media. In this regard, computer-readable mediacan be any available medium or media useable to store information andaccessible by a computing device. Some embodiments also may be practicedin distributed computing environments where operations are performed byone or more remote processing devices that are linked through acommunications network. In a distributed computing environment,software, control modules, logic, and/or logic modules may be located inboth local and remote computer storage media including memory storagedevices.

Additionally, it is to be appreciated that the embodiments describedherein illustrate example implementations, and that the functionalelements, logical blocks, modules, and circuits elements may beimplemented in various other ways which are consistent with thedescribed embodiments. Furthermore, the operations performed by suchfunctional elements, logical blocks, modules, and circuits elements maybe combined and/or separated for a given implementation and may beperformed by a greater number or fewer number of components or modules.As will be apparent to those of skill in the art upon reading thepresent disclosure, each of the individual embodiments described andillustrated herein has discrete components and features which may bereadily separated from or combined with the features of any of the otherseveral aspects without departing from the scope of the presentdisclosure. Any recited method can be carried out in the order of eventsrecited or in any other order which is logically possible.

It is worthy to note that any reference to “one embodiment” or “anembodiment” means that a particular feature, structure, orcharacteristic described in connection with the embodiment is comprisedin at least one embodiment. The appearances of the phrase “in oneembodiment” or “in one aspect” in the specification are not necessarilyall referring to the same embodiment.

Unless specifically stated otherwise, it may be appreciated that termssuch as “processing,” “computing,” “calculating,” “determining,” or thelike, refer to the action and/or processes of a computer or computingsystem, or similar electronic computing device, such as a generalpurpose processor, a DSP, ASIC, FPGA or other programmable logic device,discrete gate or transistor logic, discrete hardware components, or anycombination thereof designed to perform the functions described hereinthat manipulates and/or transforms data represented as physicalquantities (e.g., electronic) within registers and/or memories intoother data similarly represented as physical quantities within thememories, registers or other such information storage, transmission ordisplay devices.

It is worthy to note that some embodiments may be described using theexpression “coupled” and “connected” along with their derivatives. Theseterms are not intended as synonyms for each other. For example, someembodiments may be described using the terms “connected” and/or“coupled” to indicate that two or more elements are in direct physicalor electrical contact with each other. The term “coupled,” however, alsomay mean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other. Withrespect to software elements, for example, the term “coupled” may referto interfaces, message interfaces, application program interface (API),exchanging messages, and so forth.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

The disclosed embodiments have application in conventional endoscopicand open surgical instrumentation as well as application inrobotic-assisted surgery.

Embodiments of the devices disclosed herein can be designed to bedisposed of after a single use, or they can be designed to be usedmultiple times. Embodiments may, in either or both cases, bereconditioned for reuse after at least one use. Reconditioning mayinclude any combination of the steps of disassembly of the device,followed by cleaning or replacement of particular pieces, and subsequentreassembly. In particular, embodiments of the device may bedisassembled, and any number of the particular pieces or parts of thedevice may be selectively replaced or removed in any combination. Uponcleaning and/or replacement of particular parts, embodiments of thedevice may be reassembled for subsequent use either at a reconditioningfacility, or by a surgical team immediately prior to a surgicalprocedure. Those skilled in the art will appreciate that reconditioningof a device may utilize a variety of techniques for disassembly,cleaning/replacement, and reassembly. Use of such techniques, and theresulting reconditioned device, are all within the scope of the presentapplication.

By way of example only, embodiments described herein may be processedbefore surgery. First, a new or used instrument may be obtained and whennecessary cleaned. The instrument may then be sterilized. In onesterilization technique, the instrument is placed in a closed and sealedcontainer, such as a plastic or TYVEK bag. The container and instrumentmay then be placed in a field of radiation that can penetrate thecontainer, such as gamma radiation, x-rays, or high-energy electrons.The radiation may kill bacteria on the instrument and in the container.The sterilized instrument may then be stored in the sterile container.The sealed container may keep the instrument sterile until it is openedin a medical facility. A device may also be sterilized using any othertechnique known in the art, including but not limited to beta or gammaradiation, ethylene oxide, or steam.

One skilled in the art will recognize that the herein describedcomponents (e.g., operations), devices, objects, and the discussionaccompanying them are used as examples for the sake of conceptualclarity and that various configuration modifications are contemplated.Consequently, as used herein, the specific exemplars set forth and theaccompanying discussion are intended to be representative of their moregeneral classes. In general, use of any specific exemplar is intended tobe representative of its class, and the non-inclusion of specificcomponents (e.g., operations), devices, and objects should not be takenlimiting.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations are not expressly set forth herein for sakeof clarity.

The herein described subject matter sometimes illustrates differentcomponents contained within, or connected with, different othercomponents. It is to be understood that such depicted architectures aremerely examples and that in fact many other architectures may beimplemented which achieve the same functionality. In a conceptual sense,any arrangement of components to achieve the same functionality iseffectively “associated” such that the desired functionality isachieved. Hence, any two components herein combined to achieve aparticular functionality can be seen as “associated with” each othersuch that the desired functionality is achieved, irrespective ofarchitectures or intermedial components. Likewise, any two components soassociated can also be viewed as being “operably connected,” or“operably coupled,” to each other to achieve the desired functionality,and any two components capable of being so associated can also be viewedas being “operably couplable,” to each other to achieve the desiredfunctionality. Specific examples of operably couplable include but arenot limited to physically mateable and/or physically interactingcomponents, and/or wirelessly interactable, and/or wirelesslyinteracting components, and/or logically interacting, and/or logicallyinteractable components.

Some aspects may be described using the expression “coupled” and“connected” along with their derivatives. It should be understood thatthese terms are not intended as synonyms for each other. For example,some aspects may be described using the term “connected” to indicatethat two or more elements are in direct physical or electrical contactwith each other. In another example, some aspects may be described usingthe term “coupled” to indicate that two or more elements are in directphysical or electrical contact. The term “coupled,” however, also maymean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other.

In some instances, one or more components may be referred to herein as“configured to,” “configurable to,” “operable/operative to,”“adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Thoseskilled in the art will recognize that “configured to” can generallyencompass active-state components and/or inactive-state componentsand/or standby-state components, unless context requires otherwise.

While particular aspects of the present subject matter described hereinhave been shown and described, it will be apparent to those skilled inthe art that, based upon the teachings herein, changes and modificationsmay be made without departing from the subject matter described hereinand its broader aspects and, therefore, the appended claims are toencompass within their scope all such changes and modifications as arewithin the true scope of the subject matter described herein. It will beunderstood by those within the art that, in general, terms used herein,and especially in the appended claims (e.g., bodies of the appendedclaims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that when aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to claims containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations.

In addition, even when a specific number of an introduced claimrecitation is explicitly recited, those skilled in the art willrecognize that such recitation should typically be interpreted to meanat least the recited number (e.g., the bare recitation of “tworecitations,” without other modifiers, typically means at least tworecitations, or two or more recitations). Furthermore, in thoseinstances where a convention analogous to “at least one of A, B, and C,etc.” is used, in general such a construction is intended in the senseone having skill in the art would understand the convention (e.g., “asystem having at least one of A, B, and C” would include but not belimited to systems that have A alone, B alone, C alone, A and Btogether, A and C together, B and C together, and/or A, B, and Ctogether, etc.). In those instances where a convention analogous to “atleast one of A, B, or C, etc.” is used, in general such a constructionis intended in the sense one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, or C” wouldinclude but not be limited to systems that have A alone, B alone, Calone, A and B together, A and C together, B and C together, and/or A,B, and C together, etc.). It will be further understood by those withinthe art that typically a disjunctive word and/or phrase presenting twoor more alternative terms, whether in the description, claims, ordrawings, should be understood to contemplate the possibilities ofincluding one of the terms, either of the terms, or both terms unlesscontext dictates otherwise. For example, the phrase “A or B” will betypically understood to include the possibilities of “A” or “B” or “Aand B.”

With respect to the appended claims, those skilled in the art willappreciate that recited operations therein may generally be performed inany order. Also, although various operational flows are presented in asequence(s), it should be understood that the various operations may beperformed in other orders than those which are illustrated, or may beperformed concurrently. Examples of such alternate orderings may includeoverlapping, interleaved, interrupted, reordered, incremental,preparatory, supplemental, simultaneous, reverse, or other variantorderings, unless context dictates otherwise. Furthermore, terms like“responsive to,” “related to,” or other past-tense adjectives aregenerally not intended to exclude such variants, unless context dictatesotherwise.

In summary, numerous benefits have been described which result fromemploying the concepts described herein. The foregoing description ofthe one or more embodiments has been presented for purposes ofillustration and description. It is not intended to be exhaustive orlimiting to the precise form disclosed. Modifications or variations arepossible in light of the above teachings. The one or more embodimentswere chosen and described in order to illustrate principles andpractical application to thereby enable one of ordinary skill in the artto utilize the various embodiments and with various modifications as aresuited to the particular use contemplated. It is intended that theclaims submitted herewith define the overall scope.

What is claimed is:
 1. A surgical system, comprising: an electric motor,wherein said electric motor comprises a rotatable output; and a surgicalinstrument, comprising: a shaft, wherein said shaft defines alongitudinal axis; a fastener cartridge comprising a plurality offasteners removably stored therein; an anvil configured to deform saidfasteners; a closure drive configured to move said anvil toward and awayfrom said fastener cartridge, wherein said closure drive comprises arotatable closure drive portion which is rotatable about saidlongitudinal axis; a firing drive configured to deploy said fastenersfrom said fastener cartridge, wherein said firing drive comprises arotatable firing drive portion which is rotatable about saidlongitudinal axis; and a transmission, comprising: a first operatingconfiguration in which said transmission operably connects saidrotatable output to said closure drive; a second operating configurationin which said transmission operably connects said rotatable output tosaid firing drive; and a switch configured to switch said transmissionbetween said first operating configuration and said second operatingconfiguration.
 2. The surgical system of claim 1, wherein said surgicalinstrument comprises an articulation joint and an end effector, andwherein said end effector is rotatable relative to said shaft about saidarticulation joint.
 3. The surgical system of claim 1, furthercomprising: a sensor; and a control circuit assembly configured tooperate said electric motor based on a sensor input signal from saidsensor.
 4. The surgical system of claim 1, further comprising: a userinterface; and a control circuit assembly operably coupled to said userinterface, wherein said control circuit assembly is configured to causea change in said user interface.
 5. The surgical system of claim 4,wherein said change is indicative of said second operatingconfiguration.
 6. The surgical system of claim 4, wherein said userinterface comprises an indicator light.
 7. The surgical system of claim4, wherein said change is indicative of a switch to said secondoperating configuration.
 8. A surgical system, comprising: an electricmotor, wherein the electric motor comprises a rotatable output; and ashaft, wherein the shaft defines a longitudinal axis; a cartridge jawcomprising a replaceable staple cartridge, wherein the staple cartridgecomprises staples removably stored therein; an anvil configured todeform the staples; a closure drive configured to move the anvil towardthe staple cartridge, wherein the closure drive comprises a rotatableclosure drive portion which is rotatable about the longitudinal axis; afiring drive configured to deploy the staples from the staple cartridge,wherein the firing drive comprises a rotatable firing drive portionwhich is rotatable about the longitudinal axis; and a transmission,comprising: a first state in which the transmission operably connectsthe rotatable output to the closure drive; a second state in which thetransmission operably connects the rotatable output to the firing drive;and an electrically-actuated shifter configured to cause thetransmission to transition between the first state and the second state.9. The surgical system of claim 8, further comprising: a user interface;and a control circuit assembly operably coupled to the user interface,wherein the control circuit assembly is configured to cause a change inthe user interface.
 10. The surgical system of claim 9, wherein thechange is indicative of the second state.
 11. The surgical system ofclaim 9, wherein the user interface comprises an indicator light. 12.The surgical system of claim 9, wherein the change is indicative of atransition to the second state.
 13. The surgical system of claim 8,further comprising: a sensor; and a control circuit assembly configuredto operate the electric motor based on a sensor input signal from thesensor.
 14. A surgical system, comprising: a shaft, wherein the shaftdefines a longitudinal axis; a cartridge jaw comprising a replaceablestaple cartridge, wherein the staple cartridge comprises staplesremovably stored therein; an anvil configured to deform the staples; aclosure member movable through a closure stroke to move an end effectorfrom an open configuration to a closed configuration; a firing membermovable to fire the staples from the staple cartridge during a firingstroke; a drive system, comprising: a motor-driven rotatable input; atransmission configured to be transitioned between a first state and asecond state by an electrically-actuated shifter; a first motor-drivenrotatable output, wherein the closure member is operably engaged withthe first motor-driven rotatable output and is movable through theclosure stroke when the transmission is in the first state and themotor-driven rotatable input is rotated; and a second motor-drivenrotatable output, wherein the firing member is operably engaged with thesecond motor-driven rotatable output and is movable through the firingstroke when the transmission is in the second state and the motor-drivenrotatable input is rotated; and a control circuit assembly configuredto: receive an input signal; and cause the transmission to transitionfrom the first state to the second state based on the input signal. 15.The surgical system of claim 14, further comprising: a sensor, whereinthe control circuit assembly is configured to control the motor-drivenrotatable input based on a sensor input signal from the sensor.
 16. Thesurgical system of claim 14, further comprising: a user interface,wherein the control circuit assembly operably coupled to the userinterface, wherein the control circuit assembly is configured to cause achange in the user interface.
 17. The surgical system of claim 16,wherein the change is indicative of the second state.
 18. The surgicalsystem of claim 16, wherein the user interface comprises an indicatorlight.
 19. The surgical system of claim 16, wherein the change isindicative of a transition to the second state.